Processes for treating aqueous compositions comprising lithium sulfate and sulfuric acid

ABSTRACT

The present disclosure relates to processes for treating an aqueous composition comprising lithium sulfate and sulfuric acid. The processes comprise evaporatively crystallizing the aqueous composition comprising lithium sulfate and sulfuric acid under conditions to obtain crystals of lithium sulfate monohydrate and a lithium sulfate-reduced solution; and optionally separating the crystals of the lithium sulfate monohydrate from the lithium sulfate-reduced solution. The processes optionally further comprise concentrating the lithium sulfate-reduced solution under conditions to obtain an acidic condensate and a concentrate comprising sulfuric acid.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a 35 USC 371 national stage entry of PCT/CA2017/051007 filed on Aug. 28, 2017 and which claims priority on U.S. 62/380,056 filed on Aug. 26, 2016 and CA 2,940,509 filed on Aug. 26, 2016. These documents are hereby incorporated by reference in their entirety.

FIELD

The present disclosure relates to processes for treating aqueous solutions comprising lithium sulfate and sulfuric acid.

BACKGROUND

There have been some reports of the phase behavior of the binary lithium sulfate/water system and ternary lithium sulfate/sulfuric acid/water system in classic sources such as International Critical Tables and other older compilations. For example, Watts, “A Dictionary of Chemistry and the Allied Branches of Other Sciences, 1879, teaches that acid lithium sulphate, LiHSO₄, crystallises in prisms from a solution of the normal salt in sulphuric acid of sp. gr. 1.6 to 1.7; from more dilute acid, the normal salt separates again; and the acid salt melts at 160°. For example, Critical Tables contains data on the lithium sulphate/water binary. (Volume 4, p 42., 1928). Dortmund Data Bank also has some data on bisulfate.

However, there remains a need for providing an alternative to the existing processes for treating solutions comprising lithium sulfate and sulfuric acid.

SUMMARY

According to an aspect of the present disclosure, there is provided a process for treating an aqueous composition comprising lithium sulfate and sulfuric acid, said process comprising:

-   -   treating the aqueous composition comprising lithium sulfate and         sulfuric acid under conditions to obtain crystals of lithium         sulfate monohydrate and a lithium sulfate-reduced solution; and     -   optionally separating the crystals of the lithium sulfate         monohydrate from the lithium sulfate-reduced solution.

According to another aspect of the present disclosure, there is provided a process for treating an aqueous composition comprising lithium sulfate and sulfuric acid, said process comprising:

-   -   evaporatively crystallizing the aqueous composition comprising         lithium sulfate and sulfuric acid under conditions to obtain         crystals of lithium sulfate monohydrate and a lithium         sulfate-reduced solution; and     -   optionally separating the crystals of the lithium sulfate         monohydrate from the lithium sulfate-reduced solution.

According to another aspect of the present disclosure, there is provided a process for treating an aqueous composition comprising lithium sulfate and sulfuric acid, said process comprising:

-   -   evaporatively crystallizing the aqueous composition comprising         lithium sulfate and sulfuric acid under conditions to obtain         crystals of lithium sulfate monohydrate and a lithium         sulfate-reduced solution; and     -   separating the crystals of the lithium sulfate monohydrate from         the lithium sulfate-reduced solution.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following drawings, which represent by way of example only, various embodiments of the disclosure:

FIG. 1 is a schematic diagram of a process according to an example of the present disclosure;

FIG. 2 is a schematic diagram of a process according to another example of the present disclosure;

FIG. 3 shows a schematic of the ternary phase diagram for an example of the Li₂SO₄/H₂SO₄/H₂O system at 30° C.;

FIG. 4 is a plot of reported decomposition temperatures of the lithium sulphate monohydrate crystal as a function of pressure at boiling point;

FIG. 5 is a plot showing the boiling temperatures of solutions of sulphuric acid, lithium and sodium sulphates as a function of concentration [wt %] according to an example of the present disclosure;

FIG. 6 is a schematic diagram of a process according to another example of the present disclosure;

FIG. 7 is a ternary phase diagram of a process according to another example of the present disclosure;

FIG. 8 is a plot showing boiling point (° C.) as a function of total acid and salt in concentrate (wt %) at ambient pressure according to comparative examples BPR-1 (lower plot) and BPR-2 (upper plot) of the present disclosure;

FIG. 9 is a plot showing boiling point (° C.) as a function of total acid and salts in concentrate (wt %) at a pressure of 17 kPa according to comparative example BPR-3 of the present disclosure;

FIG. 10 is a plot showing boiling point (° C.) as a function of total acid and salts in concentrate (wt %) at a pressure of 3 kPa according to comparative example BPR-4 of the present disclosure;

FIG. 11 is a plot showing boiling point (° C.) as a function of total acid and salts in concentrate (wt %) at ambient pressure (BPR-1; upper plot) and at a pressure of 17 kPa (BPR-3; lower plot) in the range from 30 wt % to 84 wt % total acid and salts according to comparative examples of the present disclosure;

FIG. 12A shows a photograph of 40.6 wt % total acid and salts concentrate hot; FIG. 12B shows a photograph of 40.6 wt % total acid and salts concentrate at room temperature; FIG. 12C shows a photograph of 49 wt % total acid and salts concentrate at temperature; FIG. 12D shows a photograph of 57 wt % total acid and salts concentrate at temperature; FIG. 12E shows a photograph of 69 wt % total acid and salts concentrate at temperature; FIG. 12F shows a photograph of 75 wt % total acid and salts concentrate at temperature; FIG. 12G shows a photograph of 84 wt % total acid and salts concentrate at temperature; and FIG. 12G shows a photograph of 84 wt % total acid and salts concentrate at room temperature according to comparative example BPR-1 of the present disclosure;

FIG. 13A shows a photograph of solution 2 while heating; FIG. 13B shows a photograph of 76 wt % total acid and salts concentrate at temperature; FIG. 13C shows a photograph of 76 wt % total acid and salts concentrate at room temperature; FIG. 13D shows a photograph of 93 wt % total acid and salts concentrate at temperature; and FIG. 13E shows a photograph of 96 wt % total acid and salts concentrate at temperature according to comparative example BPR-2 of the present disclosure;

FIG. 14A shows a photograph of 66 wt % total acid and salts concentrate at temperature; FIG. 14B shows a photograph of 66 wt % total acid and salts concentrate at room temperature; FIG. 14C shows a photograph of 83 wt % total acid and salts concentrate at temperature; and FIG. 14D shows a photograph of 83 wt % total acid and salts concentrate at room temperature according to comparative example BPR-3 of the present disclosure;

FIG. 15A shows a photograph of solution 2 under vacuum, degassing; FIG. 15B shows a photograph of solution 2 heating under vacuum; FIG. 15C shows a photograph of 69 wt % total acid and salts concentrate at temperature; FIG. 15D shows a photograph of 88 wt % total acid and salts concentrate at temperature; FIG. 15E shows a photograph of 88 wt % total acid and salts concentrate at room temperature; and FIG. 15F shows a photograph of 96 wt % total acid and salts concentrate at temperature according to comparative example BPR-4 of the present disclosure;

FIG. 16A shows a photographs of the final concentrates of BPR-1; FIGS. 16B and 16C show photographs of the final concentrates of BPR-2; FIG. 16D shows a photograph of the final concentrates of BPR-3; FIG. 16E shows a photograph of the final concentrates of BPR-4; and FIG. 16F shows a photograph of the final concentrates of BPR-2 (right) and BPR-4 (left) according to comparative examples of the present disclosure;

FIG. 17A shows a photograph of the final concentrate of stage 1 at temperature; FIG. 17B shows a photograph of the final concentrate of stage 1 cooled to 30° C.; FIG. 17C shows a photograph of final concentrate of stage 2 at temperature; and FIG. 17D shows a photograph of final concentrate of stage 2 at 30° C. according to an example of a process of the present disclosure; and

FIG. 18A shows a photograph of the hot 70% concentrate of stage 1; FIG. 18B shows a photograph of the initial concentrate of stage 2; FIGS. 18C and D show photographs of large crystals in the concentrate of stage 2 after crystallizing at 30° C. overnight; FIG. 18E shows a photograph of concentrate of stage 2 after additional day at 30° C.; and FIG. 18F shows a photograph of concentrate of stage 2 re-heated to 99° C. according to an example of a process of the present disclosure.

DETAILED DESCRIPTION

I. Definitions

Unless otherwise indicated, the definitions and examples described herein are intended to be applicable to all embodiments and aspects of the present disclosure herein described for which they are suitable as would be understood by a person skilled in the art.

In understanding the scope of the present disclosure, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. The term “consisting” and its derivatives, as used herein, are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The term “consisting essentially of”, as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and/or steps as well as those that do not materially affect the basic and novel characteristic(s) of features, elements, components, groups, integers, and/or steps.

As used in this disclosure, the singular forms “a”, “an” and “the” include plural references unless the content clearly dictates otherwise. In examples comprising an “additional” or “second” component, the second component as used herein is different from the other components or first component. A “third” component is different from the other, first, and second components, and further enumerated or “additional” components are similarly different.

Terms of degree such as “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least ±5% or at least ±10% of the modified term if this deviation would not negate the meaning of the word it modifies.

The term “electromembrane process” as used herein refers, for example to a process that uses ion-exchange membrane(s) and an electric potential difference as the driving force for ionic species. The electromembrane process can be, for example (a membrane) electrodialysis or (a membrane) electrolysis. For example, the electromembrane process can be a membrane electrolysis.

II. Processes

The below presented examples are non-limitative and are used to better exemplify the processes of the present disclosure.

In the processes for treating an aqueous composition comprising lithium sulfate and sulfuric acid of the present disclosure, the aqueous composition can have any suitable concentration of lithium sulfate and sulfuric acid. For example, the aqueous composition comprising lithium sulfate and sulfuric acid can comprise from about 1 wt % to about 40 wt %, about 1 wt % to about 35 wt %, about 10 wt % to about 30 wt %, about 10 wt % to about 35 wt %, about 10 wt % to about 25 wt %, about 15 wt % to about 25 wt %, about 15 wt % to about 30 wt %, about 15 wt % to about 35 wt %, about 18 wt % to about 22 wt % or about 20 wt % lithium sulfate, based on the total weight of the aqueous composition. For example, the aqueous composition comprising lithium sulfate and sulfuric acid can comprise from about 1 wt % to about 25 wt %, about 1 wt % to about 20 wt %, about 5 wt % to about 20 wt %, about 10 wt % to about 25 wt %, about 1 wt % to about 15 wt %, about 7 wt % to about 15 wt %, about 10 wt % to about 20 wt %, or about 12 wt % sulfuric acid, based on the total weight of the aqueous composition.

The aqueous composition comprising lithium sulfate and sulfuric acid can optionally further comprise other suitable sulfates such as other alkali metal sulfates e.g. sodium sulfate and/or potassium sulfate. For example, the aqueous composition comprising lithium sulfate and sulfuric acid can further comprise sodium sulfate in an amount of up to about 10 wt %, for example from about 0.1 wt % to about 5 wt %, about 1 wt % to about 5 wt %, about 2 wt % to about 8 wt %, about 2 wt % to about 5 wt %, about 0.25 wt % to about 2.5 wt %, about 0.5 wt % to about 2 wt %, about 0.5 wt % to about 1.5 wt %, or about 1.3 wt %, based on the total weight of the aqueous composition. For example, the aqueous composition comprising lithium sulfate and sulfuric acid can further comprise potassium sulfate in an amount of up to about 10 wt %, for example from about 0.1 wt % to about 5 wt %, about 1 wt % to about 5 wt %, about 2 wt % to about 8 wt %, about 2 wt % to about 5 wt %, about 0.25 wt % to about 2.5 wt %, about 0.5 wt % to about 2 wt %, about 0.5 wt % to about 1.5 wt %, or about 1.3 wt %, based on the total weight of the aqueous composition. For example, the aqueous composition comprising lithium sulfate and sulfuric acid can further comprise sodium sulfate and/or potassium sulfate in an amount of up to about 10 wt %, for example from about 0.1 wt % to about 5 wt %, about 1 wt % to about 5 wt %, about 2 wt % to about 8 wt %, about 2 wt % to about 5 wt %, about 0.25 wt % to about 2.5 wt %, about 0.5 wt % to about 2 wt %, about 0.5 wt % to about 1.5 wt %, or about 1.3 wt %, based on the total weight of the aqueous composition.

For example, the aqueous composition comprising lithium sulfate and sulfuric acid can be from an electromembrane process for preparing lithium hydroxide. Exemplary flow diagrams for two examples of such electromembrane processes are shown in FIGS. 1 and 2.

Referring to FIG. 1, the process 10 exemplified therein is for preparing lithium hydroxide. In the process exemplified therein, a lithium-containing material 12 such as a lithium-containing ore such as β-spodumene is subjected to acid roasting and leaching steps 14 under suitable conditions to obtain an aqueous composition comprising lithium sulfate. The aqueous composition comprising lithium sulfate 16 can then be purified 18, for example to remove at least a portion of a metal impurity or a non-metallic impurity (for example Si and derivatives thereof) that has leached into the aqueous composition comprising lithium sulfate 16. For example, purification 18 can be carried out as described in PCT Application WO 2013/159194 entitled “Processes for preparing lithium hydroxide”. The aqueous composition comprising lithium sulfate then can be submitted to an electromembrane process 20 (such as a two-compartment monopolar or bipolar membrane electrolysis process, a three-compartment monopolar or bipolar membrane electrolysis process, or a combination of a two-compartment monopolar or bipolar membrane electrolysis process and a three-compartment monopolar or bipolar membrane electrolysis process) under suitable conditions for at least partial conversion of the lithium sulfate into lithium hydroxide 22 and to obtain an acidic lithium sulfate solution 24. For example, the acidic lithium sulfate solution 24 of process 10 of FIG. 1 can be the aqueous composition comprising lithium sulfate and sulfuric acid which is treated in the processes of the present disclosure.

Referring to FIG. 2, the process 110 exemplified therein is for preparing lithium hydroxide and is similar to the process 10 exemplified in FIG. 1. Several steps in the method of FIGS. 2 (112, 114, 116, 118, 120, 122 and 124) are similar to those found in the process of FIGS. 1 (12, 14, 16, 18, 20, 22 and 24). With respect to the separation step 126, such step was found to be an alternative instead of simply reusing the acidic lithium sulfate solution 124 into the acid roasting step 114 (see the dotted line between step 124 and 114). In separation step 126, water is removed in order to obtain a more concentrated acidic composition 130. It was found that such a more concentrated acidic composition that comprises sulfuric acid was efficient to carry out the acid roasting step in 114. For example, the acidic lithium sulfate solution 124 of process 110 of FIG. 2 can be the aqueous composition comprising lithium sulfate and sulfuric acid which is treated in the processes of the present disclosure. Accordingly, separation step 126 can comprise a process of the present disclosure whereby a more concentrated acidic composition 130 can be obtained which can be recycled back into the acid roasting step 114 as well as crystals of lithium sulfate monohydrate 128 recovered. The recovered lithium sulfate monohydrate can optionally be reused in electromembrane process 120.

The conditions for at least partial conversion of the lithium sulfate into lithium hydroxide may vary, and the selection of suitable conditions can be made by a person skilled in the art in light of their common general knowledge and with reference to the present disclosure. For example, processes for preparing lithium hydroxide comprising submitting a composition comprising a lithium compound to an electromembrane process are disclosed in PCT Application WO 2014/138933 entitled “Processes for preparing lithium hydroxide”; PCT Application No. WO/2015/058288 entitled “Processes and systems for preparing lithium hydroxide”; and PCT Application WO 2013/159194 entitled “Processes for preparing lithium hydroxide”

In the studies of the present disclosure, it was observed that the use of lower temperatures as a result of using vacuum in the processes helped to prevent the decomposition of the lithium sulfate monohydrate and therefore may be beneficial for recovery. Accordingly, the processes of the present disclosure can be carried out under conditions whereby decomposition of lithium sulfate monohydrate can be inhibited, for example, decomposition of the lithium sulfate monohydrate can be at least substantially prevented.

For example, the conditions to obtain crystals of the lithium sulfate monohydrate and lithium sulfate-reduced solution can comprise evaporatively crystallizing the aqueous composition comprising lithium sulfate and sulfuric acid at a temperature of less than 140° C., 130° C. or 100° C. For example, the evaporative crystallization can be carried out at a temperature of from about 40° C. to 140° C., about 40° C. to 130° C., about 45° C. to 125° C., about 50° C. to 120° C., about 50° C. to 110° C., about 50° C. to 100° C., about 40° C. to about 95° C., about 45° C. to about 85° C., about 50° C. to about 85° C., about 60° C. to about 90° C., about 60° C. to about 95° C., about 75° C. to about 85° C. or about 82° C. For example, the conditions to obtain crystals of the lithium sulfate monohydrate and lithium sulfate-reduced solution can further comprise evaporatively crystallizing the aqueous composition comprising lithium sulfate and sulfuric acid at a pressure that is lower than atmospheric pressure. For example, the evaporative crystallization can be carried out at a pressure of from about 1 kPa to about 100 kPa, 1 kPa to about 90 kPa, about 1 kPa to about 75 kPa, about 1 kPa to about 50 kPa, 5 kPa to about 75 kPa, about 1 kPa to about 25 kPa, about 1 kPa to about 20 kPa, about 5 kPa to about 15 kPa, about 10 kPa to about 25 kPa, about 15 kPa to about 20 kPa or about 16 kPa. For example, the evaporative crystallization can also be carried out at atmospheric pressure. For example, the evaporative crystallization can be carried out at a pressure of about 95 to 105 kPa, about 98 to 105 kPa or about 98 to 104 kPa.

The results of the studies of the present disclosure, suggest, while not wishing to be limited by theory, that it would be impractical to concentrate a solution such as an anolyte solution directly to a high concentration of acid and salts because the viscous gel-like nature of the mixture would most likely be prone to freezing/plugging of equipment and piping and be difficult to handle. Accordingly, in the processes of the present disclosure, lithium sulphate monohydrate crystals are removed at a suitable intermediate concentration.

For example, the conditions to obtain crystals of the lithium sulfate monohydrate and lithium sulfate-reduced solution further comprise evaporatively crystallizing the aqueous composition comprising lithium sulfate and sulfuric acid for a time in which the lithium sulfate-reduced solution contains a concentration of sulfuric acid that is less than about 65 wt %, based on the total weight of the lithium sulfate-reduced solution. For example, the evaporative crystallization can be carried out until the lithium sulfate-reduced solution has a sulfuric acid concentration of from about 30 wt % to about 65 wt %, about 30 wt % to about 50 wt %, about 40 wt % to about 65 wt %, about 40 wt % to about 50 wt %, about 45 wt % to about 65 wt %, about 45 wt % to about 60 wt %, about 50 wt % to about 65 wt %, about 45 wt % to about 55 wt %, about 40 wt % to about 60 wt %, or about 48 wt %, based on the total weight of the lithium sulfate-reduced solution.

The evaporative crystallizer can be any suitable evaporative crystallizer, the selection of which can be made by a person skilled in the art. For example, the evaporative crystallization can be carried out using a single effect evaporative crystallizer. For example, the evaporative crystallization can alternatively be carried out using a multiple effect evaporative crystallizer. For example, the evaporative crystallization can be carried out using a vapour recompression evaporator, for example, in which vapour from one effect can be used to evaporate further vapour in either a different effect, or in the same effect by either operating an additional effect at a different pressure, or compressing the vapour and recondensing in a steam chest in the same effect.

For example, the process can comprise:

-   -   cooling the lithium sulfate-reduced solution under conditions to         obtain a further portion of crystals of lithium sulfate         monohydrate and a lithium sulfate-further reduced solution         comprising sulfuric acid; and     -   separating the crystals of lithium sulfate monohydrate from the         lithium sulfate-further reduced solution comprising sulfuric         acid.

For example, the process can comprise:

-   -   cooling the crystals of lithium sulfate monohydrate and the         lithium sulfate-reduced solution under conditions to obtain a         further portion of crystals of lithium sulfate monohydrate and a         lithium sulfate-further reduced solution comprising sulfuric         acid; and     -   separating the crystals of lithium sulfate monohydrate from the         lithium sulfate-further reduced solution comprising sulfuric         acid.

For example, the cooling of the lithium sulfate-reduced solution and optionally the crystals of lithium sulfate monohydrate can be carried out at a temperature of from about 15° C. to about 80° C., about 20° C. to about 60° C., about 25° C. to about 40° C., about 25° C. to about 35° C. or about 30° C. For example, the cooling can be carried out at a pressure that is from about 1 kPa to about 100 kPa, 10 kPa to about 100 kPa, 1 kPa to about 50 kPa, 1 kPa to about 30 kPa, 1 kPa to about 20 kPa, about 0.5 kPa to about 25 kPa, about 0.5 kPa to about 20 kPa, about 1 kPa to about 10 kPa, about 1 kPa to about 5 kPa, about 0.5 kPa to about 5 kPa or about 2 kPa. For example, the cooling can also be carried out at atmospheric pressure. For example, the cooling can be carried out at a pressure of about 95 to 105 kPa, about 98 to 105 kPa or about 98 to 104 kPa

In examples of the processes of the present disclosure wherein the crystals of the lithium sulfate monohydrate are separated from the lithium sulfate-reduced solution, the separation can be carried out by any suitable means for liquid/solid separation, the selection of which can be made by a person skilled in the art. For example, the separation can comprise gravity thickening, hydrocyclones, filtration, centrifugation or combinations thereof. For example, the separation can comprise filtering a mixture of the crystals of lithium sulfate monohydrate and the lithium sulfate-reduced solution.

For example, the process can further comprise mechanically separating the lithium sulfate monohydrate from entrained lithium sulfate-reduced solution. For example, the process can further comprise washing the crystals of the lithium sulfate monohydrate. Suitable means and conditions for mechanical separation and washing can be selected by a person skilled in the art.

The results of the studies of the present disclosure, also suggest, while not wishing to be limited by theory, that while it would be impractical to concentrate a solution such as an anolyte solution directly to a high concentration, such a concentration can be carried out subsequent to the removal of lithium sulphate monohydrate crystals at the suitable intermediate concentration.

For example, the process can further comprise concentrating the lithium sulfate-reduced solution under conditions to obtain an acidic condensate and a concentrate comprising sulfuric acid.

For example, the conditions to obtain the acidic condensate and the concentrate comprising sulfuric acid can comprise concentrating the lithium sulfate-reduced solution at a temperature of from about 50° C. to about 250° C., about 50° C. to about 200° C., about 75° C. to about 200° C., about 100° C. to about 250° C., about 125° C. to about 250° C., about 100° C. to about 200° C., about 125° C. to about 225° C., about 150° C. to about 250° C., about 170° C. to about 225° C., about 170° C. to about 200° C., about 170° C. to about 190° C., about 175° C. to about 195° C., about 170° C. to about 180° C., about 180° C. to about 190° C., about 170° C., about 180° C. or about 190° C.

For example, the conditions to obtain the acidic condensate and the concentrate comprising sulfuric acid can further comprise concentrating the lithium sulfate-reduced solution at a pressure that is lower than atmospheric pressure. For example, the concentrating can be carried out at a pressure that is from about 1 kPa to about 100 kPa, 10 kPa to about 100 kPa, 1 kPa to about 50 kPa, 1 kPa to about 30 kPa, 1 kPa to about 20 kPa, about 0.5 kPa to about 25 kPa, about 0.5 kPa to about 20 kPa, about 1 kPa to about 10 kPa, about 1 kPa to about 5 kPa, about 0.5 kPa to about 5 kPa or about 2 kPa. For example, the concentrating can also be carried out at atmospheric pressure. For example, the concentrating can be carried out at a pressure of about 95 to 105 kPa, about 98 to 105 kPa or about 98 to 104 kPa.

For example, the conditions to obtain the acidic condensate and the concentrate comprising sulfuric acid can further comprise concentrating the lithium sulfate-reduced solution until a total concentration of sulfuric acid, lithium sulfate and optionally sodium sulfate of greater than about 65 wt %, for example, about 65 wt % to about 99 wt %, about 85 wt % to about 98 wt %, about 75 wt % to about 95 wt %, about 90 wt % to about 98 wt %, about 80 wt % to about 98 wt %, about 90 wt % to about 97 wt %, about 91 wt % to about 95 wt % or about 96 wt % in the concentrate comprising sulfuric acid can be reached, based on the total weight of the concentrate.

For example, the concentrate comprising sulfuric acid can be recycled to an electromembrane process for preparing lithium hydroxide. Exemplary flow diagrams for two examples of such electromembrane processes are shown in FIGS. 1 and 2 and described hereinabove.

For example, the concentrate comprising sulfuric acid can be recycled to a process step (e.g. FIG. 1: 14; FIG. 2: 114) comprising leaching a lithium-containing material with the concentrate comprising sulfuric acid. The selection of suitable conditions for such a process step can be made by a person skilled in the art. For example, processes comprising roasting a lithium-containing material with an acid are disclosed in PCT Application WO 2013/159194 entitled “Processes for preparing lithium hydroxide”.

For example, the lithium-containing material is leached with the concentrate that can be at a temperature of about 100° C. to about 170° C., about 100° C. to about 160° C., about 100° C. to about 150° C., less than about 170° C. or less than about 160° C.

For example, the lithium-containing material can be a lithium-containing ore. For example, the lithium-containing ore can comprise, consist essentially of or consist of α-spodumene, β-spodumene, lepidolite, pegmatite, petalite, eucryptite, amblygonite, hectorite, smectite, jadarite, a clay or mixtures thereof. For example, the lithium-containing ore can comprise, consist essentially of or consist of β-spodumene, jadarite or mixtures thereof. For example, the lithium-containing ore can comprise, consist essentially of or consist of β-spodumene. For example, the lithium-containing ore can be β-spodumene.

For example, the concentrate comprising sulfuric acid can be recycled to the electromembrane process for preparing lithium hydroxide without further crystallization to obtain a further portion of crystals of lithium sulfate monohydrate. Alternatively, the process can further comprise:

-   -   cooling the concentrate comprising sulfuric acid under         conditions to obtain a further portion of crystals of lithium         sulfate monohydrate and a lithium sulfate-reduced concentrate         comprising sulfuric acid; and     -   separating the crystals of the further portion of lithium         sulfate monohydrate from the lithium sulfate-reduced concentrate         comprising sulfuric acid.

For example, the conditions to obtain the further portion of crystals of lithium sulfate monohydrate and the lithium sulfate-reduced concentrate comprising sulfuric acid can comprise cooling the concentrate to a temperature of from about 5° C. to about 170° C., about 5° C. to about 150° C., about 5° C. to about 130° C., about 20° C. to about 130° C., about 15° C. to about 130° C., about 15° C. to about 50° C., about 25° C. to about 75° C., about 25° C. to about 35° C. or about 30° C. For example, the conditions to obtain the further portion of crystals lithium sulfate monohydrate and the lithium sulfate-reduced concentrate comprising sulfuric acid can comprise carrying out the cooling a pressure that is lower than atmospheric pressure. For example, the cooling can be carried out at a pressure that is from about 1 kPa to about 100 kPa, 10 kPa to about 100 kPa, 1 kPa to about 50 kPa, 1 kPa to about 30 kPa, 1 kPa to about 20 kPa, about 0.5 kPa to about 25 kPa, about 0.5 kPa to about 20 kPa, about 1 kPa to about 10 kPa, about 1 kPa to about 5 kPa, about 0.5 kPa to about 5 kPa or about 2 kPa. For example, the cooling can also be carried out at atmospheric pressure. For example, the cooling can be carried out at a pressure of about 95 to 105 kPa, about 98 to 105 kPa or about 98 to 104 kPa.

For example, the process can further comprise mechanically separating the further portion of lithium sulfate monohydrate from entrained lithium sulfate-reduced concentrate comprising sulfuric acid. For example, the process can further comprise washing the crystals of the further portion of lithium sulfate monohydrate with water. Suitable means and conditions for mechanical separation and washing can be selected by a person skilled in the art.

The following non-limiting examples are illustrative of the present disclosure:

EXAMPLES Example 1 Crystallization of Lithium Sulphate Monohydrate Crystals From Lithium Sulphate/Sulphuric Acid Solutions

An objective of the present example was to study at what points in an evaporation different forms of crystal, with different filtration characteristics, would be produced and to study how the system would behave under vacuum.

An existing process to produce lithium hydroxide from spodumene includes a step in which “concentrated” sulphuric acid is reacted with β-spodumene. The “roasting” reaction occurs in a modest temperature pug mill (200-300° C.) and produces a solid from which lithium sulphate can be extracted by leaching into water. The extent of the conversion of lithium oxide in the spodumene to sulphate has been shown to depend strongly upon the acid strength used in the roast, which may advantageously be greater than approximately 90%.

After purification, to remove, for example silica and other elements which would be deleterious to the downstream lithium hydroxide recovery, the lithium sulphate solution from the leach is processed electrochemically in a salt splitting cell to produce lithium hydroxide and an acidic lithium sulphate solution.

As an alternative to continuously purging sulphuric acid as gypsum from the electrochemical process and continuously making up significant quantities of fresh sulphuric acid, an alternative is to recycle sulphuric acid re-generated in a downstream process to the electrochemical process.

The Examples of the present disclosure study the use of an evaporative crystallization process to recover unreacted lithium sulphate from the electrochemical process and recycle it, followed by a sulfuric acid reconcentration (SARC) process to remove water from sulphuric acid before it is recycled.

Criteria for the acid reconcentration are established, for example, by the need to provide a solution with less than approximately 10% water. It is also useful to understand the composition of the balance of the recycled acids, which will contain some dissolved lithium sulphate.

Accordingly, laboratory and pilot testing is pursued in support of a conceptual design of a sulphuric acid recycle system in which an initial sulphate crystallisation is followed by an acid re-concentration. The work is aimed, for example, at identifying how much water can be removed in each phase and the characteristics of the lithium sulphate crystallization and sulphuric acid/lithium sulphate re-concentration solutions.

Testing was conducted under vacuum in addition to atmospheric pressure as operation under vacuum may impact the form of the crystals produced. Both lithium sulphate monohydrate and the anhydrous form are known to exist, with the form, while not wishing to be limited by theory, believed to be dependent upon temperature and water content of the solution. The monohydrate, while not wishing to be limited by theory, is believed to be the more filterable of the two. Work under vacuum is advantageous, for example, because the re-concentration (SARC) step is advantageously operated under these conditions so as to allow an acceptable practical metallurgy.

The objective of the testing, which is the basis of Example, was, to perform some basic laboratory experiments to identify advantageous process conditions for crystallization of relatively easily recoverable lithium sulphate monohydrate crystals from lithium sulphate/sulphuric acid solutions. In addition to identifying such conditions for crystallization, the Example 1 testing was also intended, for example, to study the boiling point rise behaviour of sulphuric acid/lithium/sodium sulphate solutions. This is advantageous to the design of both the evaporative crystallization and SARC processes.

I. Introduction

(a) Li₂SO₄/H₂SO₄/H₂O Ternary Phase Diagram

FIG. 3 shows an exemplary ternary phase diagram for the Li₂SO₄/H₂SO₄/H₂O System at 30° C. (International Critical Tables of Numerical Data—Physics, Chemistry and Technology, Volume IV (1928) pages 353 & 391). Table 1 provides the equilibrium concentration data at 30° C. for points in FIG. 3.

TABLE 1 Liquid Phase Solid Phase wt % H₂SO₄ wt % Li₂SO₄ A Li₂SO₄•H₂O 0 25.10 B 5.05 22.74 C 16.6 19.10 D 32.7 13.37 E 48.0 10.20 F Li₂SO₄•H₂O + Li₂SO₄ 55.00 13.00 G Li₂SO₄ 56.30 13.87 H Li₂SO₄ + Li₂SO₄•H₂SO₄ 62.40 18.50 I Li₂SO₄•H₂SO₄ 69.40 13.75 J 78.23 11.64 K 83.43 15.65

The diagram in FIG. 3 shows the saturation conditions at varying acid concentrations at 30° C. This data was compared to recovery results of previous testing and found to agree within 5% accuracy. While not wishing to be limited by theory, the phase diagram of FIG. 3 shows that the maximum amount of lithium sulphate recovered at this temperature would be at a sulphuric acid concentration of 48 wt % (Point E). This gives the lowest solubility of lithium (10.2 wt %), while remaining in the zone where the monohydrate crystals are the stable form, which, from previous studies, has shown to provide the best separation. Higher concentrations will begin to re-dissolve the lithium and form anhydrous and subsequently bisulphate crystals. Once above a concentration of 69.4 wt % sulphuric acid, additional lithium can be recovered. However, it will be in the form of lithium bisulphate resulting in a loss of acid.

(b) Solubility

The solubility of lithium sulphate as a function of temperature has been disclosed for water. However, it is not well established in concentrations of sulphuric acid, with the exception of the 30° C. points discussed above.

For water, the solubility of lithium sulphate has an inverse behavior in the temperature range of interest; see e.g. Critical Tables, IV, p 233. Prior to the present study it was unclear whether this also applied to the solubility in sulphuric acid solutions, which would directly influence the design operating temperature of the crystallizing/separation unit. Accordingly, tests were performed to study this solubility/temperature relationship in sulphuric acid.

(c) Decomposition of Hydrate

The monohydrate form of lithium sulphate will decompose into the anhydrous form given enough energy: Li₂SO₄·H₂O(s)↔Li₂SO₄(s)+H₂O(g)

Table 2 provides the decomposition conditions for lithium sulphate monohydrate (International Critical Tables of Numerical Data—Physics, Chemistry and Technology, Volume VII (1930) page 303).

TABLE 2 T [K] P [atm] 333.1 0.029 353.1 0.080 373.1 0.242 381.1 0.347

Other sources are consistent in giving the decomposition temperature of the hydrate as 130° C., at atmospheric pressure. See FIG. 4 for reported decomposition temperatures as a function of pressure at boiling point.

While the decomposition temperature is related to the decomposition of the crystal in solution, these parameters are thermodynamically related and one can be calculated from the other. The relative locations of the boiling point curve and the decomposition curve indicate whether the hydrated crystal, or the anhydrate, is likely stable in solution at a given composition and temperature. The stable crystal form may then change as the solution is cooled after evaporation. This has not previously been investigated experimentally. For example, the boiling point curve is a function of sulphuric acid to lithium sulphate ratio and must be developed for a specific mixture.

II. Overview of Experimental

(a) Solubility/Temperature Relationship Test

Lithium sulphate was slowly added to ˜50 wt % sulphuric acid at 50° C. to determine the solubility at this concentration/temperature condition. This concentration was chosen to be close to conditions which can realistically be expected in the crystallizer step. The detailed procedure and results of this test can be found hereinbelow in Example 1, section IV.

The final composition of the saturated solution at 50° C. was determined to be:

H₂SO₄ 43.3 wt % H₂O 43.4 wt % Li₂SO₄ 13.3 wt %

The lithium solubility is higher at 50° C. than shown on the ternary phase diagram at 30° C. of FIG. 3 (13.3 wt % versus ˜10.9 wt %). This indicates that unlike water, at this acid concentration the solubility is positively related to temperature (solubility increases as temperature increases). The solution was then heated to 70° C. and subsequently cooled to 30° C. to verify this phenomenon.

The data shows that at approximately 43 wt % sulphuric acid and between 30 and 50° C., the solubility of lithium drops by 0.12 wt % per ° C.

While not wishing to be limited by theory, this implies that it is better to operate the crystallization portion of the evaporative crystallizer step as cold as possible (within normal operating ranges available with cooling water) to maximize lithium sulphate recovery. However, the energy used to cool the solution and then reheat it for subsequent concentration may not justify colder crystallizer temperatures for example, from a cost and/or efficiency standpoint.

(b) Boiling Point Rise

Varying concentrations of solutions were made up, based on the following lithium/sodium/sulphuric acid ratios: 19.5 wt % Li₂SO₄, 1.3 wt % Na₂SO₄, 12.2 wt % H₂SO₄ and 67.0 wt % H₂O; implies non-water portion of the solution to be 59.1 wt % Li₂SO₄, 3.9 wt % Na₂SO₄ and 37.0 wt % H₂SO₄. These solutions were then slowly boiled off and the condensate collected at varying pressures. The results of these tests are summarized in this section. The detailed procedure and results of these tests can be found hereinbelow in Example 1, section V. See also FIG. 5 for the boiling temperatures for each of these tests.

BPR-1 and BPR2: The first boiling point rise test (BPR-1) investigated a range from 30 wt % to 84 wt % sulphuric acid and salts and overlapped with the second test (BPR-2) which was from 65 wt % to 96 wt %. It was split up into two tests to ensure reproducibility and achieve a greater degree of accuracy especially at the higher concentration range. Both BPR-1 and BPR-2 were performed at ambient pressure. Crystallization was first observed at 107.8° C. and a composition of 14.9 wt % H₂SO₄ and 23.9 wt % Li₂SO₄, which gives another saturation point for this system. When it reached ˜70 wt % (combined acid and salts) the mixture became very thick and had a large amount of solids. By the time it reached the final concentration of 96 wt % acid and salts, the mixture was very viscous and gel-like and difficult to manage.

BPR-3: The third boiling point rise test (BPR-3) investigated a range from 30 wt % to 83 wt % sulphuric acid and salts and was performed at −25″ of Hg (16.7 kPa absolute). This was intended to match the boiling point rise that would be seen in an evaporative crystallization step operating under vacuum. Crystallization was first observed at 69.8° C. and a composition of 14.2 wt % H₂SO₄ and 22.7 wt % Li₂SO₄, another saturation point. By the time it reached a concentration of 51.5 wt % acid and salts, the mixture was a very thick slurry.

BPR-4: The fourth boiling point rise test (BPR-4) investigated a range from 65 wt % to 96 wt % sulphuric acid and salts and was performed at −29″ of Hg (3.1 kPa absolute). This was intended to match the boiling point rise that would be seen in a SARC step which operates under deep vacuum. The data set from this test was corrupted by stopping overnight part-way through the run. Although this didn't seem to have an effect on previous tests, while not wishing to be limited by theory, it is believed that the high acid concentrations in combination with the low temperatures (i.e. below decomposition temperatures) may have caused the crystals to switch structures (i.e. bisulphate, sulphate or monohydrate) when cooled to room temperature and not reform to their previous structure when reheated to continue with the test. This would cause the solution composition and hence the boiling point to change. However, it is unlikely that in operation the anolyte solution would be concentrated entirely in a single stage without separating crystal due to its viscous nature making it difficult to handle.

(c) Evaporative Crystallizer/Filtration/Concentration Tests

From the above-described Boiling Point Rise experiments it was shown that it would be impractical from an industrial process standpoint to concentrate the anolyte solution directly to 96 wt % acid and salts without first removing crystals at some intermediate concentration. This was due to the viscous, gel-like nature of the mixture. Therefore a second set of tests was performed in which the anolyte first underwent a separate evaporative crystallization stage to concentrate to 71 wt % acid and salts.

The mixture was then cooled to 30° C. and the crystals were separated by filtration. The filtrate was then further concentrated under vacuum to a concentration of 96 wt % acid and salts in a final concentration stage.

This test was performed twice; once with the evaporative crystallizer running under vacuum and once at atmospheric pressure. In addition, a settling test was performed to quantify the settling characteristics of the monohydrate crystals. Lastly, a solids characterization test was conducted to attempt to determine the split fraction of lithium sulphate versus bisulphate crystal form. The results of all these tests are summarized in this section. The detailed procedure and results of these tests can be found in hereinbelow in Example 1, section VI.

Test 1: For this test the evaporative crystallizer was run at the same pressure as test BPR-3 (−25″ of Hg). Approximately 81% of the salts were recovered from the simulated anolyte feed, following the initial concentration to 71 wt % acid and salts (stage 1). The crystals were needle-like and translucent, while not wishing to be limited by theory, indicating primarily the monohydrate form. An additional 2.5 to 5% of the salts were recovered following stage 2. It was not confirmed whether these crystals were in the sulphate or bisulphate form. While not wishing to be limited by theory, the expectation is that the majority will be as bisulphate, which will result in lower lithium recovery and higher acid losses. As the solution cooled, a crystallization temperature was not recorded; however it was believed to be approximately 130° C.

Test 2: For this test, the evaporative crystallizer was run at atmospheric pressure (same as BPR-1). Depending on the assumed form of the crystals (anhydrous vs monohydrate), 76 to 89% of the salts were recovered from the simulated anolyte feed, following the initial concentration to 71 wt % acid and salts (stage 1). The crystals were a mixture of translucent/needle-like and white powdery solids, while not wishing to be limited by theory, if the visual appearance is an accurate indicator of the form, the actual recovery is most likely somewhere in between these two limits. An additional 1.3 to 2.7% of the salts were recovered following stage 2. The uncertainty in percent recovery is due to whether the crystals are in the sulphate or bisulphate form. While not wishing to be limited by theory, the expectation is that the majority will be as bisulphate, which will result in lower lithium recovery and higher acid losses.

Settling Test: The settling test was performed on the concentrate from test 1 after the first concentration stage, after it had been cooled to 30° C. and before filtration. The test was done by agitating the mixture in a graduated cylinder and recording the solid level over time. The crystals settled relatively quickly and reached an equilibrium level after 10 to 20 minutes. However, it was found that the solids did not compact very well and only 30 mL of filtrate was recovered by separation. This was only ˜22% of the filtrate, resulting in the crystals containing ˜50 wt % filtrate. The filtrate can, for example, be recovered via some mechanical means (e.g. filter, centrifuge, etc.) to avoid large acid losses. Washing may also, for example be used in the process. These stages can be considered in the context of the overall water and acid balances.

Solid Characterization: The solids recovered from each filtration step were characterized by inspection and by re-dissolving the crystals into water and measuring the pH. Although the quantitative split between sulphate and bisulphate was not obtained via this method, some useful observations were made. The crystals from Test 1 Stage 1 (performed at vacuum) were visually more similar to the monohydrate form than those of Test 2 Stage 1 (performed at atmospheric pressure). For Test 1 Stage 1, the final boiling temperature was 81.9° C., which is below the calculated decomposition temperature of 92° C. at 17 kPa(a). In contrast, for Test 2 Stage 1, the final boiling temperature was 127.2° C., which is at the calculated decomposition temperature of 127° C. at 101 kPa(a). This indicates that an advantage of operating under vacuum is that it helps to maintain the monohydrate crystal form when trying to maximize the lithium sulphate recovery. The crystal from Stage 2 (equivalent to the SARC) from both tests was a fine, chalky powder. While not wishing to be limited by theory, this, along with the lower pH when dissolved in water, indicates a large percentage of the crystals are in the bisulphate form, in line with these high acid concentrations.

III. Conclusions and Conceptual Flow Diagram

The following are findings which may, while not wishing to be limited by theory, have an impact on the final design:

Based on observations in the present studies, it would be impractical to concentrate the anolyte solution directly to 96 wt % acid and salts as the viscous gel-like nature of the mixture would, while not wishing to be limited by theory, most likely be prone, for example, to freezing/plugging of equipment and piping and be difficult to handle. Therefore, removal of lithium sulphate crystals at an intermediate concentration is advantageous.

The minimum solubility of lithium sulphate occurs at ˜48 wt % H₂SO₄ (58 wt % acid+salts), after which the crystals begin to switch to the anhydrous form and the solubility increases until the bisulphate crystals begin to form at ˜62 wt % H₂SO₄ (˜80 wt % acid and salts). Therefore, to maximize the recovery of lithium sulphate the evaporative crystallizer may, for example, concentrate to about 48 wt % H₂SO₄ in the solution. Based on the feed specification, the process may, for example, give a theoretical maximum lithium sulphate recovery of 87% (81% was measured in the lab).

Given the crystal properties and solution viscosities, a concentration of ˜65 wt % H₂SO₄ in the crystallizer may, for example be used. While this doesn't give the optimum crystal recovery, if this concentration is useful in an initial extraction process of lithium from spodumene, it would avoid additional unit operations by eliminating the SARC system.

Concentrations higher than 65 wt % in the crystallizer are not efficiently performed in multiple effect evaporation due to the boiling point rise. While not wishing to be limited by theory, any concentration between 65 to 96 wt % would require the addition of a SARC following the crystallizer but the chosen initial and final concentrations may have a large effect on size/cost.

When the filtrate from the crystallizer (at 48 wt % H₂SO₄) is further concentrated in the SARC (to 96 wt % acid+salts), the resulting solution may, for example, be in single phase and clear of any solid crystal particles. Upon cooling, crystals will start to form and precipitate at an estimated temperature of 130° C. If allowed to cool to 30° C., another 2.5% of the initial amount of lithium sulfate can be recovered as lithium bisulphate; however this may, for example, result in acid losses. While not wishing to be limited by theory, it is useful from the view of complexity and cost to send the acid hot to the spodumene reactor

A benefit of operating the crystallizer under vacuum is that it appears to help the crystals remain as monohydrates rather than decomposing into the anhydrous form and allows the minimum solubility point to be reached.

Settling time was in the order of minutes. However, the crystals did not compact very well and had ˜50 wt % liquid entrainment. Therefore an additional unit operation may, for example, be used to mechanically separate the entrained liquid. Also washing of the crystals may be used to minimize lithium hydroxide addition for pH adjustment due to acid carry-over. Care is used by the skilled person to ensure that the crystals are not re-dissolved.

Based on the experimental testing performed, the exemplary process flow diagram shown in FIG. 6 was created. The process 200 exemplified therein is for treating an aqueous composition comprising lithium sulfate and sulfuric acid. Referring to FIG. 6, in the process exemplified therein, the aqueous composition comprising lithium sulfate and sulfuric acid 202 is evaporatively crystallized 204 under conditions to obtain crystals of lithium sulfate monohydrate 206 and a lithium sulfate-reduced solution (filtrate 208). For example, the evaporative crystallizer 204 can be either single or multiple effect and can, for example, be operated at a pressure of about 16 kPa and a temperature (T_(f)) of about 82° C. The crystals of the lithium sulfate monohydrate 206 are optionally separated from the lithium sulfate-reduced solution 208. The evaporative crystallization 204 also produces a first acidic condensate 210. The lithium sulfate-reduced solution 208 is optionally concentrated 212 under conditions to obtain a second acidic condensate 216 and a concentrate comprising sulfuric acid 218. For example, the concentrating can be carried out by a SARC™ process which is carried out at a pressure of about 2 kPa and a temperature (T_(f)) of about 190° C.

For example, in the process 200 shown in FIG. 6, the aqueous composition comprising lithium sulfate and sulfuric acid 202 can be an anolyte feed comprising, on a 100 kg basis, about 19.5 wt % Li₂SO₄, 1.3 wt % Na₂SO₄, 12.2 wt % H₂SO₄ and 67.0 wt % H₂O. For example, about 19.7 kg of crystals of lithium sulfate monohydrate 206 can be obtained in such an example of process 200 (assuming, while not wishing to be limited by theory, an about 82% recovery and no entrainment of filtrate 208), optionally having a composition of about 94.6 wt % Li₂SO₄.H₂O and about 1.3 wt % Na₂SO₄. For example, about 26.9 kg of filtrate 208 can be obtained, optionally having a composition of about 13.1 wt % Li₂SO₄, 0.9 wt % Na₂SO₄, 45.2 wt % H₂SO₄ and 40.8 wt % H₂O. For example, about 53.4 kg of first acidic condensate 210 can be obtained which can, for example, have a pH of about 3. For example, about 10.3 kg of the second acidic concentrate 216 can be obtained which can, for example, have a pH of about 1. For example, about 16.6 kg of the concentrate comprising sulfuric acid 218 can be obtained which optionally has a composition of about 21.2 wt % Li₂SO₄, about 1.4 wt % Na₂SO₄, about 73.4 wt % H₂SO₄ and about 4.0 wt % H₂O.

FIG. 7 shows a ternary phase diagram which was developed in accordance with the examples of the present disclosure.

IV. Solubility Test—Solubility of Lithium Sulfate in 50 wt % Sulfuric Acid

(a) Summary

The solubility of lithium sulfate in 50 wt % sulfuric acid was determined experimentally to be 13.29-13.32 wt % at 50° C. The behaviour of solubility with respect to temperature was tested by heating the saturated solution from 50° C. to 70° C., followed by cooling to 30° C.

(b) Method

50 g of 50 wt % H₂SO₄ was brought into a 100 mL round bottom flask (rbf) equipped with a stir bar and condenser and was heated to 50° C. with a temperature-controlled water bath. Li₂SO₄ was then added in increments until saturated (solution turned cloudy); initially three 1 g portions were added then subsequent additions were added by spatula and weighed by difference. The cloudy solution was stirred at 50° C. for ½ hour to confirm the saturation point had been reached then 50 wt % H₂SO₄ added dropwise until the solution cleared. The solution was then heated to 70° C. and held at temperature for ˜1 hr with stirring, followed by no stirring for ½ hr. Finally, the solution was cooled to 30° C. without stirring and held at temperature for over 1 hr.

(c) Materials

Sulfuric acid solution was prepared by dilution as shown in Table 3 (analyzed by Anton Parr):

TABLE 3 Preparation of 50 wt % H₂SO₄ Initial concentration (wt %) 63.97 Final concentration (wt %) 49.97 Specific gravity 1.3973 Density (g/cm³) 1.39475 Temperature (° C.) 20.001

Lithium sulfate, anhydrous—≥98.0%, was from Aldrich Chemistry, product #62613-1KG, lot #BCBL6287V.

(d) Results/Observations

Results and observations are provided in Tables 4 and 5:

TABLE 4 Solubility of Li₂SO₄ in 50 wt % H₂SO₄ at 50° C. H₂SO₄ concentration (wt %) 49.97 Temperature (° C.) 50.0 H₂SO₄ added (g) 51.24-51.38 Li₂SO₄ added (g) 7.8728 Solubility (wt %) 13.29-13.32

TABLE 5 Effect of temperature on Li₂SO₄ solubility in 50 wt % H₂SO₄ Temperature (° C.) Appearance Conclusion 30 Colourless crystals form Past the point of in the bottom of the saturation beaker, with a clear and colourless supernatant 50 Cloudy/clear solution Saturated solution 70 Clear and colourless Saturated or below solution saturation

The anhydrous lithium sulfate was a fine, white powder The saturation point at 50° C. was observed when the solution turned cloudy. The solution remained clear and colourless when heated to 70° C. Crystallization occurred when the solution was cooled to 30° C.

V. Boiling Point Rise Tests

(a) Summary

Four experiments were performed to measure the boiling point rise (BPR) of a synthetic anolyte solution containing lithium sulfate, sodium sulfate and sulfuric acid in the range of 30-96 wt % total acid and salts at atmospheric pressure and under vacuum. Table 6 contains a summary of these tests.

TABLE 6 Summary of BPR tests Experiment Pressure Initial concentration Final Concentration BPR-1 Atmospheric 30 wt % total acid + 84 wt % total acid + salt 70 wt % water salt 16 wt % water BPR-2 Atmospheric 65 wt % total acid + 96 wt % total acid + salt 35 wt % water salt 4 wt % water BPR-3 17 kPa 30 wt % total acid + 83 wt % total acid + salt 70 wt % water salt 17 wt % water BPR-4  3 kPa 65 wt % total acid + 96 wt % total acid + salt 35 wt % water salt 4 wt % water (b) Materials

Lithium Sulfate, anhydrous—98.0%, was from Aldrich Chemistry, product #62613-1KG, lot #BCBL6287V. Sodium sulfate, anhydrous, granular, free-flowing, Redi-Dri™, ACS reagent, ≥99%, was from Sigma-Aldrich, product #798592-500g, lot #MKBV7489V. All solutions were prepared with deionized water. Sulfuric acid concentration and solution density measurements were determined using an Anton Paar DSA 5000 M Density and sound velocity meter.

(c) Equipment

A vacuum distillation apparatus was used to concentrate the solutions that was made up of a reflux condenser with a cold finger connected to a distillation condenser. Headspace temperature was measured by a thermometer before the vapours reached the cold finger. The reflux condenser and distillation condenser were connected with a kontes tap. The cold finger could be rotated to direct condensate towards the distillate collected or back towards the concentrate. Cooling water for the cold finger and distillation condenser was either tap water or was from a connected circulating, temperature-controllable water bath. The solutions were concentrated in round bottom flasks equipped with a thermometer or thermocouple. Condensate was collected into graduated bottles with ground glass necks. The solutions were heated with electric heating mantles.

(d) Experimental

Initial solutions for the experiments were prepared at 2 concentration levels with the same ratio of acid and salts. A bulk batch of solution 1 at 30 wt % acid and salts was prepared and used in tests BPR-1 and BPR-3. A fresh batch of solution 2, at 65 wt % acid and salts, was prepared directly in the flasks for each of tests BPR-2 and BPR-4 as the salts were not fully soluble at the initial concentration at room temperature. Table 7 contains data on the compositions.

TABLE 7 Compositions of synthetic anolyte solutions¹ Solution 2 Solution 2 Composition Solution 1 (BPR-2) (BPR-4) H₂O 70.01 35.11 35.11 H₂SO₄ 11.08 23.93 23.93 Li₂SO₄ 17.73 38.41 38.41 Na₂SO₄ 1.18 2.56 2.56 Acid + Salt Conc² 29.99 64.89 64.89 Density (g/cm³) 1.24 — — ¹Concentrations provided in wt %. ²Refers to the overall amount of H₂SO₄, Li₂SO₄, and Na₂SO₄ in the solutions. This was calculated based on the initial composition of the anolyte solutions. (e) Basic Procedure

The solution was charged into a round bottom flask (rbf) and the flask was equipped with a thermometer or thermocouple, boiling chip or stir bar, and electric heating mantle. The flask was connected to distillation apparatus and brought to a boil, upon which the temperature was recorded, the timer was started and collecting the condensate was begun. For tests BPR-3 and BPR-4, the distillation apparatus was connected to the vacuum pump and the system was brought to the target vacuum pressure prior to heating. The water was slowly evaporated off and the time, temperature (solution and vapour) and volume of condensate accumulated was recorded. The point at which crystals began to form was also recorded.

Due to the slow evaporation rate, each experiment was completed over two or three days. Between days, the concentrates and equipment were cooled to room temperature at atmospheric pressure. Solutions were re-heated to reflux at the desired pressure prior to re-starting condensate collection. Table 8 contains an overview of the details and modifications for each test.

TABLE 8 Details and modifications for each test Test Equipment Procedure Notes BPR-1 1 L, 2-neck rbf Test was completed over 2 days. 2 × 250 mL bottles A boiling chip was only added for for condensate the second section of the test. BPR-2 500 mL, 3-neck rbf Test was completed over 2 days. 250 mL bottle for Both magnetic stirrer and boiling condensate chip used in solution. BPR-3 1 L, 3-neck rbf Test was completed over 2 days. 2 × 250 mL bottles Boiling chip was added at the for condensate beginning of the test. BPR-4 500 mL, 3-neck rbf Test was completed over 3 days. 250 mL bottle for Magnetic stirrer was used for test. condensate (f) Results

Table 9 highlights the compositions and boiling points of the solution at their initial and final compositions. The full data collected can be found in Table 10 (BPR-1), Table 11 (BPR-2), Table 12 (BPR-3) and Table 13 (BPR-4).

TABLE 9 Summary of BPR test results Test BPR-1 BPR-2 BPR-3 BPR-4 Pressure atmospheric atmospheric 17 kPa 3 kPa Initial mass (g) 620.63 500.05 622.05 500.05 Condensate volume (mL) 400 162 396 162 Condensate mass (g) 397.23 160.87 393.2 160.71 Composition (wt %) Feed Final Feed Final Feed Final Feed Final H₂O 70.0% 15.6% 35.1% 4.0% 70.0% 17.5% 35.1% 4.0% H₂SO₄ 11.1% 31.2% 23.9% 35.4% 11.1% 30.5% 23.9% 35.4% Li₂SO₄ 17.7% 49.9% 38.4% 56.8% 17.7% 48.8% 38.4% 56.8% Na₂SO₄  1.2%  3.3%  2.6% 3.8%  1.2%  3.3%  2.6% 3.8% Total Acid + Salts 30.0% 84.4% 64.9% 96.0% 30.0% 82.5% 64.9% 96.0% Boiling Point 104° C. 148.5° C. 124.0° C. 239.0° C. 66.6° C. 113.6° C. 53.4° C. 163.0° C.

TABLE 10 Data for BPR-1 Time Temperature (° C.) Condensate Concentrate composition (wt %) Minutes Flask Head space Vol (mL) Acid + salts H₂O H₂SO₄ Li₂SO₄ Na₂SO₄ 0 103.8 99.0 0 30.0% 70.0% 11.1% 17.7% 1.2% 20 104.3 100.0 20 31.0% 69.0% 11.5% 18.3% 1.2% 27 104.8 100.0 30 31.5% 68.5% 11.6% 18.6% 1.2% 35 104.8 100.0 40 32.1% 67.9% 11.8% 19.0% 1.3% 42 105.8 100.0 50 32.6% 67.4% 12.1% 19.3% 1.3% 48 105.8 100.0 60 33.2% 66.8% 12.3% 19.6% 1.3% 61 105.8 100.0 80 34.4% 65.6% 12.7% 20.4% 1.4% 115 106.3 101.0 100 35.8% 64.2% 13.2% 21.1% 1.4% 127 106.8 101.0 120 37.2% 62.8% 13.7% 22.0% 1.5% 138 107.8 101.0 140 38.7% 61.3% 14.3% 22.9% 1.5% 151 107.8 101.0 160 40.4% 59.6% 14.9% 23.9% 1.6% 153 107.8 101.0 162 40.6% 59.4% 15.0% 24.0% 1.6% 159 107.8 100.0 174 41.7% 58.3% 15.4% 24.6% 1.6% 164 107.8 100.0 182 42.4% 57.6% 15.7% 25.1% 1.7% 169 108.8 100.5 192 43.4% 56.6% 16.0% 25.7% 1.7% 175 108.8 100.5 202 44.5% 55.5% 16.4% 26.3% 1.8% 185 109.3 100.0 212 45.6% 54.4% 16.8% 26.9% 1.8% 193 109.8 100.0 222 46.7% 53.3% 17.3% 27.6% 1.8% 203 109.8 100.0 232 47.9% 52.1% 17.7% 28.3% 1.9% 211 110.8 100.0 242 49.2% 50.8% 18.2% 29.1% 1.9% 220 111.3 99.5 252 50.5% 49.5% 18.7% 29.8% 2.0% 228 111.8 100.0 262 51.9% 48.1% 19.2% 30.7% 2.0% 236 112.8 100.0 272 53.4% 46.6% 19.7% 31.6% 2.1% 245 113.8 100.0 284 55.3% 44.7% 20.4% 32.7% 2.2% 251 114.3 100.0 292 56.6% 43.4% 20.9% 33.5% 2.2% 261 115.3 100.0 302 58.4% 41.6% 21.6% 34.5% 2.3% 268 116.8 100.0 312 60.3% 39.7% 22.3% 35.7% 2.4% 273 117.3 100.0 318 61.5% 38.5% 22.7% 36.4% 2.4% 276 118.3 100.0 322 62.3% 37.7% 23.0% 36.8% 2.5% 280 118.8 100.0 327 63.4% 36.6% 23.4% 37.5% 2.5% 284 119.8 100.0 332 64.5% 35.5% 23.8% 38.1% 2.5% 289 121.8 100.0 337 65.6% 34.4% 24.3% 38.8% 2.6% 293 122.8 101.0 342 66.8% 33.2% 24.7% 39.5% 2.6% 297 123.8 101.5 347 68.0% 32.0% 25.1% 40.2% 2.7% 302 125.3 102.0 352 69.3% 30.7% 25.6% 41.0% 2.7% 287 125.3 101.0 357 70.6% 29.4% 26.1% 41.7% 2.8% 312 126.3 101.0 362 72.0% 28.0% 26.6% 42.5% 2.8% 317 127.8 102.0 367 73.4% 26.6% 27.1% 43.4% 2.9% 322 129.8 102.0 372 74.9% 25.1% 27.7% 44.3% 2.9% 326 131.3 101.0 374 75.5% 24.5% 27.9% 44.6% 3.0% 328 131.8 101.0 376 76.1% 23.9% 28.1% 45.0% 3.0% 330 132.8 102.0 378 76.7% 23.3% 28.4% 45.3% 3.0% 332 134.3 102.0 380 77.4% 22.6% 28.6% 45.7% 3.0% 334 135.3 102.5 382 78.0% 22.0% 28.8% 46.1% 3.1% 336 136.8 103.0 384 78.7% 21.3% 29.1% 46.5% 3.1% 338 137.8 103.0 386 79.3% 20.7% 29.3% 46.9% 3.1% 341 139.3 103.5 388 80.0% 20.0% 29.6% 47.3% 3.2% 343 140.8 103.5 390 80.7% 19.3% 29.8% 47.7% 3.2% 345 141.8 103.0 392 81.4% 18.6% 30.1% 48.1% 3.2% 347 143.3 103.0 394 82.1% 17.9% 30.4% 48.6% 3.2% 350 145.3 104.0 396 82.9% 17.1% 30.6% 49.0% 3.3% 353 147.8 104.0 398 83.6% 16.4% 30.9% 49.4% 3.3% 356 150.3 104.5 400 84.4% 15.6% 31.2% 49.9% 3.3%

TABLE 11 Data for BPR-2 Time Temperature (° C.) Condensate Concentrate composition (wt %) Minutes Flask Head space Vol (mL) Acid + salts H₂O H₂SO₄ Li₂SO₄ Na₂SO₄ 0 124.0 100.0 0 64.9% 35.1% 23.9% 38.4% 2.6% 29 125.4 100.0 10 66.2% 33.8% 24.4% 39.2% 2.6% 40 126.3 101.0 15 66.9% 33.1% 24.7% 39.6% 2.6% 52 127.6 101.0 20 67.6% 32.4% 24.9% 40.0% 2.7% 60 128.4 101.0 25 68.3% 31.7% 25.2% 40.4% 2.7% 71 128.7 102.0 30 69.0% 31.0% 25.5% 40.9% 2.7% 81 128.5 102.0 36 69.9% 30.1% 25.8% 41.4% 2.8% 88 128.4 102.0 40 70.5% 29.5% 26.0% 41.7% 2.8% 95 129.6 102.0 45 71.3% 28.7% 26.3% 42.2% 2.8% 105 130.3 102.0 50 72.1% 27.9% 26.6% 42.7% 2.8% 120 132.5 101.0 60 73.7% 26.3% 27.2% 43.6% 2.9% 146 134.9 101.0 70 75.5% 24.5% 27.8% 44.7% 3.0% 146 135.2 100.0 70 75.5% 24.5% 27.8% 44.7% 3.0% 179 138.9 101.0 80 77.3% 22.7% 28.5% 45.7% 3.0% 221 142.5 101.5 90 79.1% 20.9% 29.2% 46.8% 3.1% 237 145.0 102.0 95 80.1% 19.9% 29.5% 47.4% 3.2% 254 147.6 102.0 100 81.1% 18.9% 29.9% 48.0% 3.2% 290 154.0 102.5 110 83.2% 16.8% 30.7% 49.2% 3.3% 300 157.7 102.5 115 84.3% 15.7% 31.1% 49.9% 3.3% 317 161.9 102.0 120 85.4% 14.6% 31.5% 50.5% 3.4% 330 166.0 102.0 125 86.5% 13.5% 31.9% 51.2% 3.4% 345 171.8 102.0 130 87.7% 12.3% 32.3% 51.9% 3.5% 360 177.5 102.0 135 88.9% 11.1% 32.8% 52.6% 3.5% 378 185.4 102.0 140 90.1% 9.9% 33.2% 53.3% 3.6% 389 192.1 102.0 144 91.1% 8.9% 33.6% 53.9% 3.6% 398 196.4 101.0 146 91.7% 8.3% 33.8% 54.2% 3.6% 404 199.6 101.0 148 92.2% 7.8% 34.0% 54.6% 3.6% 411 204.0 101.0 150 92.7% 7.3% 34.2% 54.9% 3.7% 422 208.0 100.0 152 93.2% 6.8% 34.4% 55.2% 3.7% 429 212.0 100.0 154 93.8% 6.2% 34.6% 55.5% 3.7% 439 217.0 100.0 156 94.3% 5.7% 34.8% 55.8% 3.7% 449 223.0 98.0 158 94.9% 5.1% 35.0% 56.1% 3.7% 461 232.0 96.0 160 95.4% 4.6% 35.2% 56.5% 3.8% 474 239.0 96.0 162 96.0% 4.0% 35.4% 56.8% 3.8%

TABLE 12 Data for BPR-3 Time Temperature (° C.) Condensate Concentrate composition (wt %) Minutes Flask Head space Vol (mL) Acid + salts H₂O H₂SO₄ Li₂SO₄ Na₂SO₄ 3 66.6 61.0 0 30.0% 70.0% 11.1% 17.7% 1.2% 31 67.3 62.0 20 31.0% 69.0% 11.5% 18.3% 1.2% 47 67.5 62.0 30 31.5% 68.5% 11.6% 18.6% 1.2% 63 67.4 62.0 40 32.1% 67.9% 11.8% 18.9% 1.3% 79 67.8 62.0 50 32.6% 67.4% 12.1% 19.3% 1.3% 97 68.8 62.5 60 33.2% 66.8% 12.3% 19.6% 1.3% 112 69.1 62.5 70 33.8% 66.2% 12.5% 20.0% 1.3% 127 69.5 62.0 80 34.4% 65.6% 12.7% 20.3% 1.4% 142 69.5 62.5 90 35.1% 64.9% 13.0% 20.7% 1.4% 158 69.7 62.5 100 35.7% 64.3% 13.2% 21.1% 1.4% 171 70.0 62.5 110 36.4% 63.6% 13.5% 21.5% 1.4% 190 70.3 62.5 124 37.5% 62.5% 13.8% 22.1% 1.5% 205 69.8 60.5 136 38.4% 61.6% 14.2% 22.7% 1.5% 212 69.5 62.5 140 38.7% 61.3% 14.3% 22.9% 1.5% 225 69.6 63.0 150 39.5% 60.5% 14.6% 23.4% 1.6% 235 69.9 63.0 160 40.4% 59.6% 14.9% 23.9% 1.6% 245 70.1 63.5 170 41.3% 58.7% 15.3% 24.4% 1.6% 256 70.3 64.0 180 42.2% 57.8% 15.6% 24.9% 1.7% 266 70.5 64.0 190 43.2% 56.8% 16.0% 25.5% 1.7% 271 70.9 64.5 200 44.2% 55.8% 16.3% 26.1% 1.7% 548 71.2 64.5 210 45.3% 54.7% 16.7% 26.8% 1.8% 271 71.6 66.0 220 46.4% 53.6% 17.1% 27.4% 1.8% 271 72.0 66.0 230 47.6% 52.4% 17.6% 28.1% 1.9% 572 72.4 66.0 240 48.8% 51.2% 18.0% 28.9% 1.9% 271 72.9 66.0 250 50.1% 49.9% 18.5% 29.6% 2.0% 588 73.3 65.0 260 51.5% 48.5% 19.0% 30.5% 2.0% 596 74.0 65.0 270 53.0% 47.0% 19.6% 31.3% 2.1% 605 74.7 65.5 280 54.5% 45.5% 20.2% 32.2% 2.1% 613 75.6 65.0 290 56.2% 43.8% 20.8% 33.2% 2.2% 272 77.0 66.0 300 57.9% 42.1% 21.4% 34.2% 2.3% 630 78.3 67.0 310 59.8% 40.2% 22.1% 35.3% 2.4% 272 81.1 69.0 320 61.8% 38.2% 22.8% 36.5% 2.4% 272 83.0 69.0 330 63.9% 36.1% 23.6% 37.8% 2.5% 273 85.0 69.0 340 66.2% 33.8% 24.4% 39.1% 2.6% 266 87.8 66.0 350 68.6% 31.4% 25.3% 40.5% 2.7% 286 90.7 66.5 360 71.2% 28.8% 26.3% 42.1% 2.8% 296 93.5 68.0 370 74.0% 26.0% 27.4% 43.8% 2.9% 267 96.7 70.0 380 77.1% 22.9% 28.5% 45.6% 3.0% 312 101.9 71.0 386 79.0% 21.0% 29.2% 46.7% 3.1% 316 107.6 73.0 390 80.4% 19.6% 29.7% 47.5% 3.2% 321 111.6 74.0 394 81.8% 18.2% 30.2% 48.4% 3.2% 323 113.6 74.0 396 82.54% 17.46% 30.5% 48.8% 3.3%

TABLE 13 Data for BPR-4 Time Temperature (° C.) Condensate Concentrate composition (wt %) Minutes Flask Head space Vol (mL) Acid + salts H₂O H₂SO₄ Li₂SO₄ Na₂SO₄ 0 53.4 35.0 0 64.9% 35.1% 23.9% 38.4% 2.6% 17 54.4 37.5 10 66.2% 33.8% 24.4% 39.2% 2.6% 33 55.0 38.5 20 67.6% 32.4% 24.9% 40.0% 2.7% 52 57.7 39.0 30 69.0% 31.0% 25.5% 40.9% 2.7% 76 63.7 42.0 40 70.5% 29.5% 26.0% 41.7% 2.8% 77 56.6 36.0 40 70.5% 29.5% 26.0% 41.7% 2.8% 100 59.7 39.5 50 72.1% 27.9% 26.6% 42.7% 2.8% 134 68.5 43.0 60 73.7% 26.3% 27.2% 43.6% 2.9% 145 70.0 43.5 65 74.6% 25.4% 27.5% 44.1% 2.9% 154 79.1 49.0 70 75.5% 24.5% 27.8% 44.7% 3.0% 171 79.9 50.5 80 77.3% 22.7% 28.5% 45.7% 3.0% 188 84.5 52.5 90 79.1% 20.9% 29.2% 46.8% 3.1% 206 93.2 54.0 100 81.1% 18.9% 29.9% 48.0% 3.2% 214 97.4 54.0 105 82.1% 17.9% 30.3% 48.6% 3.2% 222 101.3 55.0 110 83.2% 16.8% 30.7% 49.2% 3.3% 244 113.2 54.5 120 85.4% 14.6% 31.5% 50.5% 3.4% 264 129.2 60.0 130 87.7% 12.3% 32.3% 51.9% 3.5% 269 132.9 60.0 132 88.2% 11.8% 32.5% 52.2% 3.5% 271 94.4 44.0 134 88.6% 11.4% 32.7% 52.5% 3.5% 276 97.3 42.0 136 89.1% 10.9% 32.9% 52.8% 3.5% 288 106.9 42.0 140 90.1% 9.9% 33.2% 53.3% 3.6% 302 115.1 40.0 144 91.1% 8.9% 33.6% 53.9% 3.6% 314 122.3 39.5 148 92.2% 7.8% 34.0% 54.6% 3.6% 335 136.3 39.5 154 93.8% 6.2% 34.6% 55.5% 3.7% 343 143.4 39.0 156 94.3% 5.7% 34.8% 55.8% 3.7% 348 146.9 39.0 158 94.9% 5.1% 35.0% 56.1% 3.7% 357 155.4 37.5 160 95.4% 4.6% 35.2% 56.5% 3.8% 365 163.0 37.0 162 96.0% 4.0% 35.4% 56.8% 3.8%

The point at which crystals formed is only noted for test BPR-1 and BPR-3 as the other two tests contained undissolved solids at their initial composition level (Table 14). This point was determined as the concentration level at which point precipitation was first noted in the concentration flask. It can also be considered as a range between the measurement at which the solids were observed and the previous measurement taken.

TABLE 14 Crystallization point for tests BPR-1 and BPR-3 Test BPR-1 BPR-3 Crystallization Temp (° C.) 107.8 69.8 H₂O 59.6% 61.6% H₂SO₄ 14.9% 14.2% Li₂SO₄ 23.9% 22.7% Na₂SO₄ 1.6% 1.5% Total Acid + Salts 40.4% 38.4%

The graphs in FIGS. 8-11 show the rises in boiling points for each test (FIG. 8: BPR-1 and BPR-2; FIG. 9: BPR-3; FIG. 10: BPR-4; FIG. 11: BPR-1 and BPR-3). The boiling point is the temperature measured in the solution or slurry which is denoted as the “flask temperature” in the data tables.

Table 15 contains data relating to pH measurements of the condensate obtained from tests BPR-1 to BPR-4.

TABLE 15 Condensate pH measurements Test fraction mass (g) volume (mL) density (g/mL) pH measured Appearance BPR-1 1 160.05 162 0.99 4.3 Clear, colourless BPR-1 2 237.18 238 1.00 2.3 Clear, colourless BPR-2 1 160.87 162 0.99 1.68 Clear, slightly yellow BPR-3 1 248.68 250 0.99 3.77 Clear, colourless BPR-3 2 144.52 146 0.99 2.42 Clear, colourless BPR-4 1 160.71 162 0.99 1.58 Clear, slightly yellow (g) Observations

The appearance of the solutions and point of crystal formation was observed for each of the tests. Due to the insulation required when heating the solution, constant observations were not made throughout the experiment.

BPR-1: The first part of the concentration was from 30-41% total acid and salts and no stir bar or boiling chips were used. The solution was clear and colourless initially and boiled smoothly. At 40.4% total acid and salts, the mixture began to bump and boiled more vigorously and crystals were observed in the concentrate. The crystals were clear, needle-like, and settled quickly to the bottom of the flask when the mixture was not agitated. The supernatant was clear and colourless. The first part of the concentration was stopped at 40.6% total acid and salts (FIG. 12A) and cooled overnight. Additional crystals formed at room temperature with nice, crystalline structures (FIG. 12B).

The second part of the concentration was from 41-84% total acid and salts. A boiling chip was added to the concentrating flask for the second part of the test. Some of the solids that had been present at room temperature re-dissolved when the mixture reached reflux. The mixture continued to boil quite vigorously and bump even with the boiling chip. From 40.6% to 56.6%, the appearance of the concentrate was very similar except for a slight increase in the amount of solids visible (see, for example, FIG. 12C which shows concentrate at 49% and FIG. 12D which shows concentrate at 57%). The solids were fine, needle-like white crystals which settled as soon as the boiling stopped. The supernatant was clear and colourless. At 69.3%, a larger solids layer was visible in the concentrate as shown in FIG. 12E. The solids appeared to be white and fine and the supernatant was slightly opaque and yellowed. Some solids were stuck to the walls of the flask. At 74.9%, the concentrate seemed quite viscous as shown in FIG. 12F. The final concentrate contained 84.4% total acid and salts and had a large layer of white solids in the bottom with a supernatant that was clear and colourless once the solids had settled to the bottom of the flask as shown in FIG. 12G. When cooled to room temperature, more solids precipitated with a very small layer of supernatant remaining as shown in FIG. 12H.

BPR-2: The initial mixture was a thick, white slurry. The slurry was prepared using a magnetic stir plate, and the stirring was maintained for the test. The first part of the concentration was from 65-76% total acid and salts. Several hours of heating were required until the mixture reached reflux and condensate collection was started. Some of the initial solids dissolved with heating based on the visual appearance of the concentrate. However at no point did all of the solids go into solution (see, for example: FIG. 13A). During the concentration, the mixture appeared to be a white, bubbling slurry. At 71.3% the mixture began to boil and bump very vigorously, so the heating was lowered slightly. At 75.5% the hot concentrate had a layer of white solids that settled to the bottom of the flask and a clear and slightly yellow supernatant (FIG. 13B). The concentration was stopped at this point and cooled overnight. At room temperature (FIG. 13C) the whole mixture had crystallized. There appeared to be two layers of solids. The bottom layer had finer, white solids. The top layer which appeared to correspond to the supernatant layer contained larger, white, needle-like crystals.

The second part of the concentration was from 76-96% total acid and salts. As the concentrate was heated to reflux, some of the crystals re-dissolved to form a slurry. The white slurry boiled mildly as it was concentrated. The appearance was quite consistent during the second part of the concentration. At 92.7%, mostly white solids were visible in the flask with a small amount of clear, yellow supernatant (FIG. 13D). At 96.0% concentrated, the test was stopped. The concentrate was a thick, white, bubbling slurry when hot. As the solids settled, but the mixture was still hot, a layer of slightly opaque and pale yellow supernatant was visible (see, for example: FIG. 13E).

BPR-3: BPR-3 was the first test performed under vacuum. The cold finger and condenser were cooled using a circulation water bath set at 10° C. instead of tap water which was used in the previous tests. The first part of the concentration was from 30-66% total acid and salts. The solution was clear, colourless and boiled mildly until 37.5%. At 38.4% the first solids were observed in the solution and they settled to the bottom of the flask when boiling stopped and were needle-like crystals. At 42.2%, the concentrate began to boil more vigorously. The receiving flask was switched at 50.1% concentration with the system being maintained at temperature and under vacuum. The amount of solids increased as the concentration proceeded. The supernatant was clear and colourless and the mixture boiled quite vigorously. At 66.2% total acid and salts the concentration was stopped (FIG. 14A) and the system was brought to atmospheric pressure and cooled to room temperature (FIG. 14B) overnight.

The second part of the concentration was from 66.2-82.5% total acid and salts (see FIG. 14C for 83% concentrate at temperature). The system was put under vacuum and heated to reflux before collection was started. The final concentrate had a layer of white solids at the bottom of the flask with a supernatant layer that appeared viscous, slightly opaque and pale yellow (FIG. 14D).

BPR-4: The initial slurry at 65% total acid and salts was very thick and sticky; the stir bar in the flask was not able to fully mix the system. A glass stir rod was used to assist in stirring while the solution was prepared. The slurry swelled significantly to almost fill the whole flask when first put under vacuum. The solution was then brought to the target vacuum of 3 kPa slowly to allow the swelling to subside. While not wishing to be limited by theory, the swelling was likely due to degassing of the slurry (FIG. 15A). The slurry was then brought to reflux under vacuum (FIG. 15B) and the first part of the concentration was from 64.9-70.5% total acid and salts (see, for example 15C, showing 69% concentrate at temperature). While not wishing to be limited by theory, it is likely that stirring did not occur during this step due to how thick the slurry was throughout. There were no visible changes in the solution from room temperature to at reflux. The 70.5% concentrate was cooled to room temperature and left at atmospheric pressure overnight. At room temperature, three distinct layers were visible in the 70.5% concentrate. The bottom layer was a solid white mass, encompassing the stir bar, stuck to the bottom of the flask. The middle layer was the largest and contained slurried/suspended solids that appeared to be a mix of needle-like crystals and finer, white solids. At the top there was a very thin layer of clear, colourless supernatant visible. The top two layers were easily stirred. The bottom solid layer was not easily stirred and could not be broken into smaller pieces with a spatula.

The second stage of the concentration was from 70.5-88.2% total acid and salts (see: FIG. 15D for 88% concentrate at temperature and FIG. 15E for 88% concentrate at room temperature). At reflux the solids mass did not dissolve or break up immediately. At approximately 75%, the boiling subsided and it took a while for reflux to resume. However, when the boiling and distilling resumed, the mixture appeared to be well-mixed and the stir bar was able to mix the solution. The distillation proceeded smoothly for the rest of the concentration.

The third stage of the concentration was from 88.2-96.0% total acid and salts. The solids appeared to fully disperse in the slurry at boiling. The final concentrate was a thick and opaque slurry (FIG. 15F).

Comparison of final concentrates: The concentrate from BPR-1 contained crystal-like, translucent white crystals with a clear, colourless supernatant (FIG. 16A). A thick slurry formed when the bottle was agitated. The concentrate from BPR-2 was a thick slurry with a very thin layer of viscous supernatant right at the surface (FIG. 16B). The very top layer of the solids and slurry could be scraped and mixed with the spatula (FIG. 16C), and the majority of the solids were in a solid mass at the bottom of the flask. The concentrate from BPR-3 was settled into three layers. The top layer was a thin supernatant, the middle layer appeared to contain crystalline, white solids and the bottom layer appeared to be settled solids that were finer than the middle layer. With agitation all three layers mixed together into a thick slurry (FIG. 16D). The concentrate from BPR-4 cooled into a solid mass with no excess liquid visible. The solids appeared to be in two layers (FIG. 16E). The solids at the top appeared to be more crystal-like and the solids at the bottom appeared to be finer and less crystalline than the top later. See also FIG. 16F for a side-by-side comparison of BPR-2 (right hand rbf) and BPR-4 (left hand rbf).

VI. Two-Stage Concentration and Filtration Tests

(a) Summary

A two-stage concentration and filtration test of a synthetic anolyte solution was completed at atmospheric pressure and under vacuum. Stage one of the experiment was the concentration of a synthetic anolyte solution from 33% to 71% total acid and salts. This was completed under vacuum at 17 kPa and at atmospheric pressure. The 71° A solution was cooled to 30° C. and filtered. In the second stage, the resulting filtrate was concentrated further to 96% total acid and salts under a vacuum at 3 kPa for both experiments. The final concentrate was cooled to 30° C. to precipitate solids and filtered.

(b) Materials

Lithium Sulfate, anhydrous—≥98.0%, was from Aldrich Chemistry, product #62613-1KG, lot #BCBL6287V. Sodium sulfate, anhydrous, granular, free-flowing, Redi-Dri™, ACS reagent, ≥99%, was from Sigma-Aldrich, product #798592-500g, lot #MKBV7489V. All solutions were prepared with deionized water.

(c) Equipment

The concentration steps were performed using the same equipment that was used for the boiling point rise tests described in Example 1, section IV.

(d) Experimental

State 1 Concentration and Filtration

An initial solution of lithium sulfate, sodium sulfate and sulfuric acid was prepared in deionized water. A round bottom flask was charged with solution and equipped with a thermocouple, distillation apparatus and electric heating mantle. For test 1, the foregoing set-up was connected to a vacuum pump and the system brought to 17 kPa. The mixture in the flask was brought to a boil and water distilled off to reach the target concentration. The final mass of condensate and concentrate was recorded, the contents of the concentrating flask were transferred to a 500 mL Erlenmeyer flask and the flask submerged in a 30° C. circulating water bath overnight. The 30° C. concentrate was vacuum filtered through a 1.5 μm glass microfiber filter and the filtrate used to rinse any solids stuck to the glassware from previous steps into the filter cake. Finally, the filtrate was isolated, the filter cake rinsed thoroughly with ethanol and the crystals dried.

Stage 2 Concentration and Filtration

A known amount of filtrate from stage 1 was transferred into a 250 mL, 3-neck, round bottom flask. The flask was equipped with a thermocouple, distillation apparatus and electric heating mantle, connected to a vacuum pump and brought to 3 kPa. The mixture in the flask was brought to a boil and water distilled off to reach the target concentration. The final mass of condensate and concentrate was then recorded. The cooling and filtration steps of stage 2 were different in tests 1 and 2 as follows:

Test 1: The contents of the concentrating flask were transferred to a 250 mL Erlenmeyer flask and submerged in a 30° C. circulating water bath overnight. The 30° C. concentrate was vacuum filtered through a 1.5 μm glass microfiber filter. A portion of the filtrate was used to rinse any solids stuck to the glassware from previous steps into one Erlenmeyer, but not combined with the filter cake. The filter cake was rinsed thoroughly with ethanol and the crystals left to dry.

Test 2: The final concentrate was left to cool to ambient temperature with stirring. A camera equipped with a timer was used to take pictures at one minute intervals to note the temperature and appearance of concentrate while cooling. The concentrate was then left at 30° C. overnight to crystallize solids. The concentrate was heated to 99° C. slowly in an oil bath and observed to watch the solids re-dissolve. The concentrate was then cooled to 30° C. and vacuum filtered through a 1.5 μm glass microfiber filter. The filter cake was rinsed thoroughly with ethanol and the crystals left to dry.

Solids Settling Test

This was performed on the concentrate from test 1 stage 1 after cooling to 30° C. The 30° C. concentrate was transferred to a 250 mL graduated bottle. The concentrate was then agitated to fully suspend solids. The bottle was set on a bench and a timer started. The level of solids was recorded over time.

(e) Results

Table 16 contains a summary of the conditions of the tests:

TABLE 16 Summary of conditions for tests Test Pressure Initial BP (° C.) Final BP (° C.) 1 stage 1 17 kPa  60.6 81.9 1 stage 2 3 kPa 41.6 228 2 stage 1 atmospheric 104.8 127.2 2 stage 2 3 kPa 40.8 222

Test 1 stage 1 (17 kPa): The initial solution was prepared by mass. The amount of concentrate was determined by mass at the end of the concentration step and the composition was calculated by, while not wishing to be limited by theory, assuming that all condensate removed was water. The recovered and dried solids appeared as homogenous, translucent, needle-like crystals and were assumed, while not wishing to be limited by theory, to be all Li₂SO₄ monohydrate. The filtrate amount and composition was calculated as the difference between the concentrate and the recovered solids. The filtration was performed so that all solids were accounted for in the filter cake by rinsing all glassware into the filter with filtrate after the initial filtration. The total filtrate was calculated as the difference in mass between the concentrate and the recovered solids. The recovered filtrate was less than the calculated total due to transfer losses and filtrate entrained in the filter cake prior to rinsing with ethanol. Table 17 contains an overview of the composition data for test 1 stage 1.

TABLE 17 Composition data for test 1 stage 1 concentration and filtration Recovered Total Recovered Initial condensate concentrate solids filtrate filtrate Component (g) Total 700.28 373.86 326.42 137.70 188.72 159.89 Li₂SO₄ 136.59 136.59 118.31 18.29 15.49 Na₂SO₄ 9.11 9.11 0.00 9.11 7.72 H₂SO₄ 85.40 85.40 85.40 72.36 H₂O 469.17 373.86 95.31 19.39 75.92 64.32 Acid + salts 231.11 231.11 112.80 95.57 Li₂SO₄ as 158.98 158.98 137.70 21.28 18.03 monohydrate¹ Composition (wt %) Total 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% Li₂SO₄ 19.5% 0.0% 41.8% 85.9% 9.7% 9.7% Na₂SO₄ 1.3% 0.0% 2.8% 0.0% 4.8% 4.8% H₂SO₄ 12.2% 0.0% 26.2% 0.0% 45.3% 45.3% H₂O 67.0% 100.0% 29.2% 14.1% 40.2% 40.2% Acid + salts 33.0% 0.0% 70.8% 0.0% 59.8% 59.8% Li₂SO₄ as 22.7% 0.0% 48.7% 100.0% 11.3% 11.3% monohydrate¹ ¹calculated based on amount of Li₂SO₄ present.

Test 1 stage 2 (3 kPa): The filtrate from stage 1 was used as the initial solution for stage 2. The test was done with 150 g of the filtrate, with the remaining recovered filtrate set aside. The final masses of the condensate and the final concentrate were measured. A mass lost was calculated as the difference between the initial filtrate and the sum of the concentrate and condensate samples. While not wishing to be limited by theory, the mass lost is likely due to condensation that remained on the walls of the distillation apparatus. The filtration step in stage 2 was difficult as the final concentrate was very viscous. It was not possible to use the filtrate to transfer all of the solids stuck to the glassware into the filter, so the amount of solids recovered only represents what was initially transferred into the filter after the solids were crystallized at 30° C. Transfer losses are not accounted for in either the solids or the filtrate from this step. Table 18 contains an overview of the composition data for test 1 stage 2.

TABLE 18 data for test 1 stage 2 concentration and filtration Sample Mass (g) Initial filtrate 150.01 Condensate 56.65 Final concentrate 89.99 Mass lost 3.37 Recovered solids 7.16

Test 2 stage 1 (atmospheric pressure): The compositions of the initial solution and final compositions were determined as in test 1. Table 19 contains an overview of the composition data for test 2 stage 1 concentration.

TABLE 19 Composition data for test 2 stage 1 concentration Initial condensate concentrate Component (g) Total 851.86 454.2 397.66 Li₂SO₄ 166.07 166.07 Na₂SO₄ 11.08 11.08 H₂SO₄ 101.87 101.87 H₂O 572.84 454.2 118.64 Acid + salts 279.02 279.02 Li₂SO₄ as monohydrate¹ 193.29 193.29 Composition (wt %) Total 100.0% 100.0% 100.0% Li₂SO₄ 19.5% 0.0% 41.8% Na₂SO₄ 1.3% 0.0% 2.8% H₂SO₄ 12.0% 0.0% 25.6% H₂O 67.2% 100.0% 29.8% Acid + salts 32.8% 0.0% 70.2% Li₂SO₄ as monohydrate¹ 22.7% 0.0% 48.6% ¹calculated based on amount of Li₂SO₄ present.

The solids isolated by filtration were not homogenous; instead they appeared to be a mixture of translucent crystals similar to test 1, and amorphous white powdery solids. The composition of the solids was not determined, so the exact composition of the filtrate was also unknown. While not wishing to be limited by theory, the composition was assumed to be somewhere between if the solids were determined to be fully anhydrous Li₂SO₄ or fully Li₂SO₄ monohydrate. The two cases are laid out in Table 20.

TABLE 20 Possible compositions of solids from test 2 filtration 1 All Anhydrous Li₂SO₄ All Li₂SO₄ Monohydrate Crystals Total filtrate Crystals Total filtrate Component (g) Total 157.46 240.2 157.46 240.2 Li₂SO₄ 157.46 8.61 135.29 30.78 Na₂SO₄ 0.00 11.08 0.00 11.08 H₂SO₄ 101.87 101.87 H₂O 0.00 118.64 22.17 96.47 Acid + salts 121.56 143.73 Li₂SO₄ as 157.46 35.83 monohydrate¹ Composition (wt %) Total 100.0% 100.0% 100.0% 100.0% Li₂SO₄ 100.0% 3.6% 85.9% 12.8% Na₂SO₄ 0.0% 4.6% 0.0% 4.6% H₂SO₄ 0.0% 42.4% 0.0% 42.4% H₂O 0.0% 49.4% 14.1% 40.2% Acid + salts 0.0% 50.6% 0.0% 59.8% Li₂SO₄ as 100.0% 14.9% monohydrate¹ ¹calculated based on amount of Li₂SO₄ present.

Test 2 stage 2 (3 kPa): As the exact composition of the filtrate from stage 1 was not known, the end point of the stage 2 concentration was based on the boiling point measured in test 1 stage 2 as the conditions and final target concentration were the same for both tests. The concentration was stopped when the boiling point reached 222° C. The volume of condensate collected at that point fell in the target range calculated based on anhydrous lithium sulfate or lithium sulfate monohydrate being removed by filtration in stage 1. Table 21 contains an overview of the calculations for amount of condensate to remove and Table 22 contains an overview of the data for test 2 stage 2 concentration.

TABLE 21 Calculations for target amount of condensate to remove Initial Mass of concentrate (g) 183.44  183.44 Li₂SO₄ species anhydrous monohydrate acid + salt content 50.6% 59.8% Target Final acid + salt content   96%   96% Mass of concentrate (g) 96.70 114.34 mass of condensate (g) 86.74  69.10

TABLE 22 Data for test 2 stage 2 concentration Sample Mass (g) Initial filtrate 183.44 Condensate 71.6 Final concentrate 108.45 Mass lost 3.39

The filtration was performed after the precipitation and solubility testing on the final concentrate. The concentrate was transferred directly from the flask used for the experiment to the filter. Only a small amount of concentrate remained on the flask walls. This was transferred into the final cake with ethanol during the ethanol wash of the filter cake. Table 23 contains an overview of the data for test 2 stage 2 filtration.

TABLE 23 Data for test 2 stage 2 filtration Sample Mass (g) Concentrate 108.45 Solids recovered 4.766 Filtrate recovered 100.24 Mass lost 3.444

Crystallization and solubility: Two experiments were performed to test the crystallization and solubility properties of the test 2 stage 2 concentrate. Tables 24 and 25 contain an overview of the results of these experiments.

TABLE 24 Observation of concentrate when cooled from final boiling point to 30° C. Temper- Time ature Appearance  0 min 212° C. Clear, pale yellow solution. No solids crystallized. 91 min  30° C. No change in appearance. Stirring has slowed, which suggests increased viscosity of the concentrate.

TABLE 25 Observation of concentrate when heated from room temperature to 99° C. Temperature Appearance Room temperature Thick, opaque, slightly yellow slurry 66° C. Less viscous, opaque, slightly yellow slurry 85° C. No change in appearance 99° C. No change in appearance Note: Concentrate was held at each temperature for at least 30 minutes

Solids characterization: The solids recovered from each filtration step were characterized by inspection and by measuring the pH of the solids in solution. A solution was made up of each solid in deionized water. Table 26 contains an overview of the properties of the filtered solids.

TABLE 26 Properties of filtered solids Test Stage Appearance Mass (g) Final vol (mL) Conc. (g/L) pH 1 1 Needle-like, translucent, white crystals 2.50 25 100 3.57 1 2 Powdery, white, chalky clumps of solids 1.00 10 100 2.64 2 1 A mix or needle-like crystals and white 2.51 25 100 2.89 powdery solids 2 2 Powdery, white, chalky clumps of solids 0.50 5 100 1.84

Condensate: Table 27 contains an overview of the results of pH measurements of condensate samples.

TABLE 27 pH measurements of condensate samples Condensate pH Test 1 stage 1 2.84 Test 1 stage 2 1.05 Test 2 stage 1 3.05 Test 2 stage 2 1.18

Solids setting test: The settling test was performed on the concentrate from test 1 stage 1 after it has been cooled to 30° C. and before filtration. The test was done in triplicate. The concentrate was at 30° C. at the beginning of the first test and all three tests were done in succession at room temperature. Table 28 contains the setting test data for test 1 concentrate.

TABLE 28 Settling test data for test 1 concentrate at 30° C. Test 1 Test 2 Test 3 Liquid level = 177 mL Liquid level = 174 mL Liquid Level = 175 mL Time solid level Time solid level Time solid level (min) (mL) (min) (mL) (min) (mL) 0.4 170 0.6 165 0.2 170 1.8 160 1.3 160 1.6 160 3.7 150 2.8 150 3.4 150 9.0 146 4.1 145 6.7 146 16.3 145 6.9 140 11.4 144 20.3 142 15.0 138 20.0 143 22.4 140 25.0 142 30.0 141 35.0 141 45.0 141 (f) Observations

Test 1 stage 1: The final concentrate at 70.8 wt % total acid and salts contained white crystals and had a clear, colourless supernatant layer when the solids settled (FIG. 17A). When cooled to 30° C., the solids layer was larger and with a thin layer of supernatant (FIG. 17B).

Test 1 stage 2: The filtrate used as the initial solution for the concentration experiment was clear and colourless (FIG. 17C). The final concentrate was clear, yellow/brown and contained no solids at the final boiling point. The concentrate was cooled in the flask, then re-heated to reflux temperature under vacuum to re-dissolve solids so that the concentrate could be transferred to an Erlenmeyer flask for crystallization. Solids formed in the concentrate when cooled to 30° C. The resulting slurry was very thick with solids suspended throughout (FIG. 17D). The filtration was very slow and additional solids appeared to precipitate in the filtrate as the filtration proceeded. The filtrate was viscous and slightly yellow in colour.

Test 2 stage 1: The final concentrate at 70% acid and salts was a slurry with a layer of white solids that settled to the bottom of the flask with a clear and colourless supernatant (FIG. 18A). The concentrate was transferred to an Erlenmeyer flask for cooling and crystallization of solids. Initially the final concentrate was allowed to cool partially, however large chunks of solids formed that could not be transferred. The concentrate had to be heated to >100° C. to re-dissolve the large chunks of solids so that the concentrate could be fully transferred. The concentrate was cooled to ˜75° C. at ambient temperature and then cooled to 30° C. in the water bath. The solution was maintained at 30° C. for 2 hours and then filtered.

Test 2 stage 2: The filtrate used as the initial solution for this experiment was clear and colourless (FIG. 18B). It turned from colourless to yellow, but remained clear throughout the experiment. No crystallization was observed in the initial cooling of the concentrate from boiling point to 30° C. The concentrate was left at 30° C. overnight, and crystals were observed in the concentrate. The crystals were translucent, very large, and the colour of the concentrate (FIGS. 18C-D). The supernatant was thick and clear. The concentrate was then left in the 30° C. water bath for the day. At the end of the day, the slurry appeared creamy with finer white solids in the concentrate in addition to the initial large crystals (FIG. 18E). After heating to 99° C. (FIG. 18F) and then cooling back to 30° C., the concentrate was thick and white/beige and no large crystals were apparent. The concentrate filtered very slowly. The filtrate was clear and colourless and the cake was opaque. Air was pulled through the filter cake until it looked like a thin layer of white/beige, powdery solids partially clumped together. After washing with ethanol and drying, the filter cake was made up of white, powdery and lumpy solids.

Tables 29, 30, 31 and 32 contain additional concentration data for test 1 stage 1, test 1 stage 2, test 2 stage 1 and test 2 stage 2, respectively.

TABLE 29 Test 1 stage 1 concentration data Time (min) Boiling point (° C.) Head space (° C.) Condensate (mL) 0 60.6 55 0 30 62.3 57 55 54 62.6 58 102.5 81 62.9 58 160 105 63.7 58 200 123 64.7 58 225 144 65.7 58 255 160 66.9 58 275 184 69.1 59 305 206 71.9 60 330 223 75.2 61 350 237 79.2 62 365 245 81.9 62.5 374

TABLE 30 Test 1 stage 2 concentration data Time (min) Boiling point (° C.) Head space (° C.) Condensate (mL) 0 41.6 24 0 32 50.6 30 10 58 60.1 34 20 81 73.1 42 30 107 96.3 44 40 137 135.4 49 50 151 169.4 50.5 54 165 219 66 56 185 228 208 57

TABLE 31 Test 2 stage 1 concentration data Time (min) Boiling point (° C.) Head space (° C.) Condensate (mL) 0 104.8 99 0 29 106.2 100 50 56 107.2 100 105 83 107.6 101 150 115 108.5 101 185 143 109.5 101 220 178 110.1 101 245 207 111.3 101 275 257 113.9 102 325 318 117.7 103 375 353 121 103 405 392 127.2 104 445 394 127.2 104 446 396 127.5 104 450 400 127.2 104 454

TABLE 32 Test 2 stage 2 concentration data Time (min) Boiling point (° C.) Head space (° C.) Condensate (mL) 0 40.8 28.5 0 23 51.2 34 10 56 57.2 32 24 79 62.7 30 32 102 70.9 31 40 127 88.8 34 50 155 129.5 39 60 173 158.3 41 66 187 186.5 44 70 192 200 45 72 198 210 49 73 201 215 49 73 204 220 48 73 205 222 47.5 73

Example 2 Behaviour of Sulphuric Acid/Lithium Sulphate Solutions

The objective of the Example 2 testing is to study the behaviour of sulphuric acid/lithium sulphate solutions in a test campaign in a pilot SARC system. The key goals of the pilot testing are to:

-   -   Determine heat transfer behaviour of sulphuric acid/lithium         sulphate solutions and, in so doing, develop process design         basis information relevant to Example 1 and commercial scale         SARCs to allow for scale-up;     -   Demonstrate ability to continuously re-concentrate a sulphuric         acid/lithium sulphate solution in a few dedicated campaign         trials. Each campaign includes the evaporation and subsequent         crystallization of anolyte solution followed by concentration of         the filtrate from the crystallization; and     -   Confirm short-term material suitability in concentrated, hot         solutions of sulphuric acid and lithium sulphate.

While the present disclosure has been described with reference to examples, it is to be understood that the scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

All publications, patents and patent applications are herein incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. Where a term in the present application is found to be defined differently in a document incorporated herein by reference, the definition provided herein is to serve as the definition for the term. 

What is claimed is:
 1. A process for treating an aqueous composition comprising lithium sulfate and sulfuric acid, said process comprising: evaporatively crystallizing the aqueous composition comprising lithium sulfate and sulfuric acid under conditions to obtain crystals of lithium sulfate monohydrate and a lithium sulfate-reduced solution, and to at least substantially prevent decomposition of said crystals of lithium sulfate monohydrate into anhydrous lithium sulfate, wherein said conditions comprise carrying out evaporative crystallization at a temperature of about 40° C. to 100° C., at a pressure of about 1 kPa to about 90 kPa and optionally separating the crystals of the lithium sulfate monohydrate from the lithium sulfate-reduced solution.
 2. The process of claim 1, wherein the aqueous composition comprising lithium sulfate and sulfuric acid comprises from about 1 wt % to about 35 wt % lithium sulfate, based on the total weight of the aqueous composition.
 3. The process of claim 1, wherein the aqueous composition comprising lithium sulfate and sulfuric acid comprises from about 1 wt % to about 25 wt % sulfuric acid, based on the total weight of the aqueous composition.
 4. The process of claim 1, wherein the aqueous composition comprising lithium sulfate and sulfuric acid comprises from about 5 wt % to about 20 wt % sulfuric acid, based on the total weight of the aqueous composition.
 5. The process of claim 1, wherein the aqueous composition comprising lithium sulfate and sulfuric acid comprises from about 7 wt % to about 15 wt % sulfuric acid, based on the total weight of the aqueous composition.
 6. The process of claim 1, wherein the aqueous composition comprising lithium sulfate and sulfuric acid further comprises sodium sulfate and/or potassium sulfate in an amount of up to about 10 wt %, based on the total weight of the aqueous composition.
 7. The process of claim 1, wherein the evaporative crystallization is carried out at a temperature of from about 50° C. to 100° C.
 8. The process of claim 1, wherein the evaporative crystallization is carried out at a temperature of from about 40° C. to about 95° C.
 9. The process of claim 3, wherein the evaporative crystallization is carried out at a temperature of from about 75° C. to about 85° C.
 10. The process of claim 1, wherein the evaporative crystallization is carried out at a temperature of about 82° C.
 11. The process of claim 1, wherein the evaporative crystallization is carried out at a pressure of from about 1 kPa to about 75 kPa.
 12. The process of claim 8, wherein the evaporative crystallization is carried out at a pressure of from about 10 kPa to about 25 kPa.
 13. The process of claim 9, wherein the evaporative crystallization is carried out at a pressure of from about 15 kPa to about 20 kPa.
 14. The process of claim 9, wherein the evaporative crystallization is carried out at a pressure of about 5 kPa to about 15 kPa.
 15. The process of claim 8, wherein the conditions to obtain crystals of the lithium sulfate monohydrate and lithium sulfate-reduced solution further comprise evaporatively crystallizing the aqueous composition comprising lithium sulfate and sulfuric acid for a time in which the lithium sulfate-reduced solution contains a concentration of sulfuric acid that is less than about 65 wt %, based on the total weight of the lithium sulfate-reduced solution.
 16. The process of claim 15, wherein the evaporative crystallization is carried out until the lithium sulfate-reduced solution has a sulfuric acid concentration of from about 30 wt % to less than about 65 wt %, based on the total weight of the lithium sulfate-reduced solution.
 17. The process of claim 15, wherein the evaporative crystallization is carried out until the lithium sulfate-reduced solution has a sulfuric acid concentration of from about 40 wt % to about 50 wt %, based on the total weight of the lithium sulfate-reduced solution.
 18. The process of claim 1, wherein the process comprises: cooling the lithium sulfate-reduced solution under conditions to obtain a further portion of crystals of lithium sulfate monohydrate and a lithium sulfate-further reduced solution comprising sulfuric acid; and separating the crystals of lithium sulfate monohydrate from the lithium sulfate-further reduced solution comprising sulfuric acid.
 19. The process of claim 18, wherein the cooling is carried out at a temperature of from about 20° C. to about 60° C.
 20. The process of claim 1, wherein the process further comprises concentrating the lithium sulfate-reduced solution under conditions to obtain an acidic condensate and a concentrate comprising sulfuric acid.
 21. The process of claim 20, wherein the concentrating is carried out at a temperature of from about 170° C. to about 200° C.
 22. The process of claim 21, wherein the concentrating is carried out at a pressure that is from about 0.5 kPa to about 25 kPa.
 23. The process of claim 20, wherein the conditions to obtain the acidic condensate and the concentrate comprising sulfuric acid further comprise concentrating the lithium sulfate-reduced solution until a total concentration of sulfuric acid, lithium sulfate and optionally sodium sulfate and/or potassium sulfate of greater than about 65 wt % in the concentrate comprising sulfuric acid is reached, based on the total weight of the concentrate.
 24. The process of claim 20, wherein the process further comprises: cooling the concentrate comprising sulfuric acid under conditions to obtain a further portion of crystals of lithium sulfate monohydrate and a lithium sulfate-reduced concentrate comprising sulfuric acid; and separating the crystals of the further portion of lithium sulfate monohydrate from the lithium sulfate-reduced concentrate comprising sulfuric acid. 